Volvo - Manutenzione e Motore

Operator's ManualMaintenance and Engine

ForewordThis manual contains information concerning the safe operation of yourvehicle. It is extremely important that this information is read and un-derstood before the vehicle is operated. This manual also contains aconsiderable amount of information concerning the vehicle, such as ve-hicle identification, Preventive Maintenance recommendations and a logfor your service records. Please keep this in the vehicle at all times. In-formation from other component manufacturers is supplied in separatemanuals in the Owner’s Package.

NOTE! It is important that this manual stays with the vehicle when itis sold. Important safety information must be passed on to the new cus-tomer. The service information contained in this manual gives theowner important information about maintaining the vehicle but is notintended as a substitute for the Preventive Maintenance Service Manualand must not be regarded as such.

The National Highway Traffic Safety Administration (NHTSA) andVolvo Trucks North America, Inc. should be informed immediately ifyou believe that the vehicle has a defect that could cause a crash, in-jury 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 Transportation, Washington, DC 20590.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-20 154722

© 2001 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced,stored in retrieval system, or transmitted in any forms by any means,electronic, mechanical, photocopying, recording or otherwise, withoutthe prior written permission of Volvo Trucks North America, Inc..

Contents

General Information ............................................................................ 1Information For the Owner ................................................................. 1

Safety Information ............................................................................... 3Proper Maintenance Procedure ........................................................... 3Injury Prevention ................................................................................. 6Engine Damage Prevention ............................................................... 15Electric System Damage Prevention ................................................ 17Speed Restrictive Tires ..................................................................... 19Reporting Safety Defects .................................................................. 20

General Engine Design Information ............................................... 21Engine Overview D7 ......................................................................... 21Engine Compartment Overview D7 ................................................. 23Engine Overview, D12 ...................................................................... 25Engine Compartment Overview, D12 .............................................. 27Engine Features ................................................................................. 29VECTRO II Customer Parameter Values, D7 .................................. 30VECTRO II Customer Parameter Values, D12 ................................ 31Engine Variants, D7 .......................................................................... 32Engine Variants, D12 ........................................................................ 33Engine Data ....................................................................................... 34

Engine Storage ................................................................................... 35Engine Storage .................................................................................. 35

Cooling System ................................................................................... 37General Coolant Information ............................................................ 37Water Specification ........................................................................... 44Additives ............................................................................................ 45Antifreeze .......................................................................................... 46

Fuel System ........................................................................................ 54Fuel Safety Reminders ...................................................................... 54Diesel Fuel Specification .................................................................. 55Fuel Additives ................................................................................... 59Alternative Fuels ............................................................................... 62

Oil System ........................................................................................... 63

Engine Oil ......................................................................................... 63Oil Sampling ..................................................................................... 74

Short-Haul Service Schedule for VN-Series................................... 78General and Check-Charts ................................................................ 78Maintenance Categories .................................................................... 82

Long-Haul Service Schedule for VN-Series ................................... 88General and Check-Charts ................................................................ 88

Maintenance ....................................................................................... 91Engine Maintenance .......................................................................... 91Flushing Cooling System, D7 ........................................................ 117Flushing Cooling System, D12 ...................................................... 120Turbo and Charge Air Cooler ......................................................... 122Replacing Fuel Filters, Volvo Engines ........................................... 124Fuel System Service ....................................................................... 125Transmission and Rear Axle Maintenance ..................................... 135Steering and Brakes Maintenance .................................................. 138Electrical System Maintenance ....................................................... 144Tires, Wheels and Hub Maintenance ............................................. 146Chassis Maintenance ....................................................................... 150Cab Maintenance ............................................................................. 152Lubrication, VN .............................................................................. 157Viscosity and Capacity Tables ........................................................ 161

Literature .......................................................................................... 170Service Assistance and Manuals .................................................... 170

Service Charts .................................................................................. 172Scheduled Services ......................................................................... 172Repair Record ................................................................................. 175Tire Record ...................................................................................... 181Fuel and Oil Record ....................................................................... 192

Index .................................................................................................. 199

Warning Label Information

IMPORTANTBefore driving this vehicle, be certain that you have read and thatyou fully understand each and every step of the driving and han-dling information in this Maintenance Manual. Be certain that youfully understand and follow all safety warnings before servicing anycomponent on this vehicle.

IT IS IMPORTANT THAT THE FOLLOW-ING INFORMATION CONCERNINGLABELS BE READ, UNDERSTOODAND ALWAYS FOLLOWED.

The following types of labels are usedthroughout this manual:

NOTE! A note defines an operating proce-dure, practice, condition, etc., which isessential to proper operation of the vehicle.

CAUTION

A caution label directs the operator’sattention to unsafe practices where per-sonal injury is not likely but propertydamage could occur. The caution label isin black type on a white backgroundwith a black border.

WARNING

A warning label directs the operator’sattention to unsafe practices which couldresult in personal injury or severe dam-age to the vehicle. The warning label isin black type on a gray backgroundwith a black border.

A danger label directs the operator’s at-tention to unsafe practices which couldresult in serious personal injury or death.The caution label is in white type on ablack background with a black border.

General Information 1

Information For the OwnerIf there are questions on the maintenanceand performance of your vehicle, pleasediscuss them with your Volvo Truck dealer.Your authorized dealer is required to havetrained mechanics, special tools and spareparts to fully service your vehicle. Ifnecessary, your dealer will contact the man-ufacturer for assistance.

In addition to this Maintenance Manual,there may be additional instruc-tion/operator’s manuals supplied bycomponent manufacturers. These manualsare placed in the Owner’s Package andplaced in the cab. Be sure to read all themanuals thoroughly before operating thevehicle.

Also, various safety labels may be placedon components by the component manufac-turer. Be sure to read and follow theselabels to prevent damage to the vehicle,personal injury or even death.

Information in this manual refers to Volvocomponents and Volvo drivetrain. Informa-tion concerning non-Volvo engines and/ordrivetrains can be obtained by contactingthe respective manufacturer.

Establish a Preventive Maintenance Pro-gram with the help of your local VolvoTruck dealer. A Preventive MaintenanceProgram makes it possible to maximize theamount of time your vehicle is up and run-ning, resulting in longer component life.This makes for a safer vehicle by reducingany mechanical failures due to poor mainte-nance practices.

NOTE! Federal law requires manufacturersto notify owners of its products in the eventof a Federal Motor Vehicle Safety Standardor if a safety related defect is discovered. Ifyou are not the original owner of this vehi-cle, please notify us about the change inownership at the address below or throughan authorized Volvo Truck dealer. This isthe only way we will be able to contactyou if necessary.

Volvo Trucks North America, Inc.

P. O. Box 26115

Greensboro, NC 27402–6115

United States of America

2 General Information

Do Not Removethis manual from the ve-hicle. It contains important operational andsafety information that is needed by alldrivers and owners of this vehicle.

This Maintenance Manual covers all Volvovehicles manufactured by Volvo TrucksNorth America, Inc., including the wholechassis and all Volvo manufactured compo-nents. Specific maintenance information onvendor components, manufactured by, forexample: Cummins, Detroit Diesel, Fuller,Meritor, etc., see the respective manufac-turer’s service and maintenance literature.

This manual, together with manuals forspecific components, for example, Volvoengine, Cummins engine, Eaton transmis-sion, etc., contain important information tobe able to operate this vehicle safely. Theycontain advice and instructions which willenable you to get the operating economyand performance that you expect from thisquality vehicle.

All information, illustrations and specifica-tions contained in this manual are basedupon the latest product information avail-able at the time of publication. If anyquestions arise concerning the current sta-tus of Federal or state laws, the appropriateFederal or state agency should be contacted.

Volvo Trucks North America, Inc. reservesthe right to make changes at any time or tochange specifications or design without no-tice and without incurring obligation.

Safety Information 3

Proper Maintenance ProcedureDuring MaintenanceWhenever performing maintenance or re-pair, attach a DO NOT OPERATE orsimilar warning label or sign to the ignitionkey or prominently displayed on the instru-ment panel.

Do not allow unauthorized personnel on,around or in the vehicle when mainte-nance or repair is being performed.

Before working on a vehicle, set theparking brakes, place the transmission inneutral, and block the wheels. Failure todo so can result in unexpected vehiclemovement and can cause serious per-sonal injury or death.

WARNING

Do not attempt to repair or service thisvehicle without having sufficient train-ing, correct service literature and theproper tools. Failure to follow this couldlead to personal injury or making yourvehicle unsafe.

WARNING

Diesel engine exhaust and some of itsconstituents are known to the state ofCalifornia to cause cancer, birth defectsand other reproductive harm.

Do not breathe the engine exhaust gas. Itcontains carbon monoxide, which has nocolor or odor. Carbon monoxide is adangerous gas which can cause uncon-sciousness and death.

• When operating the engine in an en-closed area, vent the exhaust to theoutside.

• Before servicing your vehicle, applythe parking brakes and adequatelychock the wheels in order to preventunintended vehicle movement. If theservice procedure requires the parkingbrakes to be released — recheck to en-sure that the wheels are adequatelychocked to prevent all forward and/orrearward movement.

• Do not use combustible substances inor around the engine either during re-pair or maintenance or when runningthe engine.

Never operate the engine in an areawhere hydrocarbon vapors (gasoline, forexample) are present or are suspected tobe present. Hydrocarbon vapors can en-ter the air intake and overspeed theengine, causing severe engine damageand/or an explosion and fire. Seriouspersonal injury or death could occur.

4 Safety Information

• Do not wear loose clothing or jewelrythat can catch or get snagged by partsor moving components on the engine.Also wear all protective equipment re-quired by the job conditions, such asprotective glasses, hearing protection,etc.

• Make certain that all protective coversand guards are in place and secured.

• Never put maintenance fluids intoglass containers since glass containerscan break.

• Report all problems in a timely man-ner before they threaten the safety ofoperating the vehicle.

• Do not work on the engine while it isrunning.

• Tag the vehicle with the DO NOTOPERATE sign. Make sure other pro-tective locks and covers are in theirproper place.

• Disconnect the batteries wheneverperforming any repairs or before ser-vicing the electrical system.

• DO NOT use high amperage elec-tronic starting devices forjump-starting the engine. Rely on con-ventional battery charging for chargingthe batteries or jump-start with thehelp of a start battery.

• DO NOT attempt repairs you do notunderstand or have the proper tools for.

• When starting an engine after repairshave been made to the fuel or injectionsystem, prepare equipment for shuttingoff the engine intake air and/or fuelsupply (to stop the engine), in casethere is an overspeed on start-up.

• Start the engine only from the driverseat. Never operate the starter motoracross the starter terminals or the bat-teries as this could by-pass the engineneutral-start system as well as causingdamage to the electrical or electronicsystems.

Never try to operate or work on thisvehicle while under the influence of al-cohol. Your reflexes can be affected byeven a small amount of alcohol. Drink-ing and operating this vehicle can leadto an accident, causing serious personalinjury or death.


Compressed Air and Water

WARNING

Compressed air can cause personal in-jury. When using compressed air forcleaning, wear a protective face shield,protective clothing and protective shoes.Pressurized water could cause particlesand/or hot water to be sprayed in yourdirection and cause personal injury. Themaximum air pressure must be below30 psi (200 kPa) for cleaning purposes.

Asbestos InformationNOTE! The Volvo engine and its replace-ment parts shipped from the factory areasbestos free. Volvo recommends the use ofonly genuine Volvo spare parts.Never use any parts that contain or arethought to contain asbestos. Exposure to as-bestos fibers can create serious health risks,including death.

Fluid Penetration

WARNING

Always use a piece of paper orcardboard when checking for a leak. Es-caping fluid under high pressure, even apin-hole sized leak, can penetrate bodytissue, causing serious injury.


Injury PreventionBurn Prevention

Engine Parts

WARNING

Hot engine. Keep yourself clear of allhot engine parts and/or fluids. A hot en-gine and/or fluids can cause seriousburns.

Do not touch any part of the engine whileit is hot. Allow the engine to cool beforeany repair or maintenance is performed onthe engine.

Do not raise the engine hood or cab if yousee or hear steam or coolant escaping fromthe engine compartment. Wait until steamor coolant cannot be seen or heard beforeraising the hood or cab.

Do not remove the coolant fill cap if thecoolant in the surge tank is boiling. Also,do not remove the cap while the engine andradiator are still hot. Scalding fluid andsteam may be blown out under pressure ifthe cap is taken off too soon.

Relieve all pressure in air, oil, fuel or cool-ing systems before any lines, fittings orrelated items are disconnected or removed.

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CoolantTo prevent personal injury, do not climb upon the engine to remove the filler cap. Usea suitable, properly positioned ladder toreach up to the cap. At normal operatingtemperature, the engine coolant is very hotand under pressure. If pressure is relievedrapidly in a hot cooling system, the hotcoolant can turn into steam. Any contactwith hot coolant or steam can cause severeburns. The radiator and all heating systemand radiator lines and hoses contain hotcoolant.

WARNING

Under some conditions, the ethyleneglycol in antifreeze can be combustible.To help avoid being burned when addingcoolant, do not spill coolant on the ex-haust system or engine parts that may behot.

Verify coolant level only by the markingson the expansion tank. Open the filler caponly after the engine has been stopped andcooled down. Remove the filler cap slowlyto relieve pressure.

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Oils

WARNING

Hot engine. Keep yourself clear of allhot engine parts and/or fluids. A hot en-gine and/or fluids can cause seriousburns.

Hot oil can cause severe burns. Do not al-low hot oil to contact the skin. Whenchanging oil, wear protective gloves.

Batteries

WARNING

Always wear eye protection when work-ing around batteries to prevent the riskof injury due to contact with sulfuricacid or an explosion.

WARNING

Battery posts, terminals and relatedaccessories contain lead and lead com-pounds, chemicals known to the State ofCalifornia to cause cancer and reproduc-tive harm. Wash hands after handling.

Battery electrolyte contains acid and cancause injury. Avoid contact with the skinand eyes. Wash hands after touching batter-ies and connectors. Use of gloves isrecommended. Always wear protectiveglasses when working with batteries.


Fire or Explosion Prevention

The diesel engine will operate on anyfuel which enters the cylinder, whether itis from the injectors or from the air in-take system. Therefore, if any solvent isused to flush out the air cleaner element,the engine may overspeed duringstart-up. Engine damage and severeinjury and/or death from burns or explo-sion can occur.

The engine should not be operated in anarea where combustible gases are suspectedto be in the air. These could be drawn intothe engine through the engine air intakesystem and could cause the engine to over-speed with possible serious damage to theengine and bodily injury or propertydamage.

W0001526

Excessive heat may cause the pressur-ized components of the air conditionedsystem to explode. Never weld, solder,steam clean or use a gas torch near anypart of the air conditioning system. Se-vere injury or death may occur from anexplosion.

Do not pressure or leak test R134a refriger-ant for air conditioning or servicingequipment using compressed air. Somemixtures of air and R134a refrigerant havebeen shown to be combustible at elevatedpressures. These mixtures, if ignited, cancause injury or property damage. Consultthe R134a Material Safety Data Sheet(MSDS) for additional information.


To avoid potential fire hazard, do notservice any part of the fuel system whilesmoking or in the presence of flames,sparks or hot surfaces, or when workingon an operating engine. Failure to followthese precautions can result in fire. Toguard against burns from direct contactwith hot fuel, wear adequate protectiveclothing (face shield, heavy gloves andapron, etc.) when working on a hot en-gine.

All fuels, most lubricants and some coolantmixtures are flammable. Diesel fuel isflammable. Gasoline is flammable. Themixture of diesel and gasoline fumes is ex-tremely explosive. Do not smoke whilerefueling or when in a refueling area.

WARNING

Do not store fuel containers in the vehi-cle. They may leak, explode and causeor feed a fire. Empty or full, theypresent a hazard that may lead to a fireand personal injury.

Keep all fuels and lubricants stored inproperly marked containers and away fromall unauthorized personnel. Store oily ragsor other flammable material in a protectivecontainer, in a safe place. Remove allflammable material such as fuel, oil andother substances before they accumulate onthe engine. Do not expose the engine toflames, driving over burning ground, etc., ifat all possible. Do not weld or flame cut onor around pipes or tubes that containflammable fluids.

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Exhaust heat shields may be installed toprotect oil or fuel carrying lines and pipesfrom hot exhaust parts. To protect from pipeor seal failure, install heat shields correctly.

Provide adequate and proper waste oil dis-posal. Always dispose of waste liquidsaccording to Federal and local regulations.Oil and fuel filters should be properly in-stalled and housing covers tightened to theproper torque when being changed.

Starting Aids

Do not use ether or similar starting aidsin a Volvo or any other engine with apreheater. The Volvo engine is equippedwith a preheater. Introduction of ether orother combustible material in the intakemanifold could cause a fire or explosion,resulting in personal injury or death.

DO NOT use etheror other combustiblestarting aids on engines that have a heaterelement or other heating devices installedin the intake manifold for heating intake airat cold-starts.

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Fire ExtinguisherAnytime work is being done to the fuelsystem or any other area where flammablesubstances are being used, have a fire extin-guisher available and know how to use it.Inspect and have it serviced as recom-mended on its instruction label.


Respiratory Hazard Prevention

Do not breathe the engine exhaust gas. Itcontains carbon monoxide, which has nocolor or odor. Carbon monoxide is adangerous gas which can cause uncon-sciousness or death.

WARNING

Diesel engine exhaust and some of itsconstituents are known to the state ofCalifornia to cause cancer, birth defectsand other reproductive harm.

Always work in a well ventilated space ifthe engine needs to be running and use ahose to route the exhaust to the outside.

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Poisonous Substances

Risk of poisoning. Ethylene and propy-lene glycol are toxic. To preventpersonal injury or death, do not drinkcoolant. Use proper eye and hand pro-tection when handling. Keep coolant orconcentrated antifreeze out of reach ofchildren and animals.

Cooling system supplemental additive con-tains alkali. To prevent personal injury,avoid contact with the skin and eyes. DONOT drink coolant of any concentration.


Crushing or Cutting Prevention

Before working on or inspecting a vehi-cle, set the parking brakes, place thetransmission in neutral and block thewheels. Failure to do so can result in un-expected vehicle movement and cancause serious personal injury or death.

WARNING

Do not work near the fan with the en-gine running. The engine fan can engageat any time without warning. Anyonenear the fan when it turns on could beseriously injured. Before turning on theignition, be sure that no one is near thefan.

Support equipment and components prop-erly when working beneath them. Neverattempt adjustments while the engine isrunning unless otherwise specified for theservice procedure. To help prevent an acci-dent caused by moving parts, workcarefully around them. Guards, covers andshields should be in place whenever main-tenance is not being performed. Keepobjects away from moving fan blades. Theywill throw or cut any object or tool thatfalls or is pushed into them.

Inspect the fan blade assembly before ser-vice for cracks or loose mounting beforestarting the engine. Never stand beside arotating fan assembly, particularly at highfan speeds.

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Wear protective glasses when striking ob-jects to avoid injury to your eyes. Chips orother debris can fly off objects that arestruck. Make sure no one can be injured byflying debris before striking any object.

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Climbing Up and Down

Always have three limbs (one foot andtwo hands or two feet and one hand) incontact with the vehicle at all timeswhen entering or exiting the cab or thearea behind the cab. Failure to followthis guideline may result in a fall thatcan cause serious personal injury ordeath.

DO NOT climb up on or jump off from theengine or stand on components that cannotsupport your weight. Use an adequate lad-der or scaffolding, suitably situated. Do notuse top of engine or cowling ledge asfoothold when reaching on top of cab.Clean steps, handholds and areas of the ve-hicle you will be working on or around.Refer to the Operator’s Manual for properentry and exit procedures.

Always use a three-point stance (twohands — one foot or one hand — twofeet) whenever climbing up or down.


Engine Damage Prevention

Before Starting the Engine


Inspect engine for potential hazards. Makesure all protective guards and covers areproperly installed if an engine needs to bestarted to make adjustments or checks. Tohelp prevent an accident by moving partswork carefully around them.

DO NOT disable or bypass automaticalarm/shutoff circuits. They are provided toprevent personal injury and engine damage.

The diesel engine will operate on anyfuel which enters the cylinder, whether itis from the injectors or from the air in-take system. Therefore, if any solvent isused to flush out the air cleaner element,the engine may overspeed duringstart-up. Engine damage and severeinjury and/or death from burns or explo-sion can occur.

Make provisions for shutting off the engineintake air or fuel supply to stop the engineif there is an overspeed on start-up afterperforming repair or maintenance on it.

Always consult the proper Volvo ServiceManual before any repair is attempted.


Engine StartingDO NOT start the engine or move any ofthe controls or disengage the parking brakeif the warning tag “DO NOT OPERATE” isattached to the ignition key or located onthe dash. Check with the person who at-tached the tag before starting.

Make sure no one is working on or close tothe engine or components driven by the en-gine before starting it. Always make aninspection of the engine before and afterstarting.

Diesel engine exhaust contains products ofcombustion which may be harmful to yourhealth. Always start and operate the enginein a well-ventilated area, and if in an en-closed area, vent the exhaust to the outside.

Start the engine only from the driver seat inthe cab. Never start the engine by shortingacross the starter motor terminals or batter-ies to start the engine as this could bypassthe engine neutral-start system as well asdamage the electrical and electronic sys-tem. Always start the engine according tothe required engine starting procedure de-scribed in this operator’s manual to preventmajor engine component damage and per-sonal injury.

Starting Aids

Do not use ether or similar starting aidsin a Volvo or any other engine with apreheater. The Volvo engine is equippedwith a preheater. Introduction of ether orother combustible material in the intakemanifold could cause a fire or explosion,resulting in personal injury or death.

W0001484


Electric System Damage Prevention

Electric and Electronic SystemsNever disconnect any charging unit circuitor battery circuit cable from the batterywhen the charging unit is operating. Aspark can cause the flammable vapor mix-ture of hydrogen and oxygen to explode.

To prevent potential sparks from ignitingcombustible gases produced by some bat-teries, attach the negative (-) terminal lastwhen hooking up and remove the negativeterminal first after the engine has started.Check regularly around the engine and en-gine compartment for loose or frayed wires.Have all loose or frayed electrical wirestightened, repaired or replaced before oper-ating the vehicle.

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WARNING


Grounding PracticesProper grounding for vehicle and engineelectrical and electronic systems is neces-sary for proper vehicle and engineperformance and reliability. Impropergrounding will result in uncontrolled andunreliable electrical paths.

Uncontrolled engine electrical circuit pathscan result in damage to main bearings,crankshaft journals surfaces and aluminumcomponents. Uncontrolled electrical circuitpaths can also cause electrical noise whichmay degrade vehicle and radio performance.

Operating engines without the engine-to-frame ground strap installed can causedamage to the engine. To prevent electricaldischarge damage, check to make sure theengine’s electrical system has an engine-to-frame ground strap. All ground connectionsshould be tight and free of corrosion.


Electronic Engine Control SystemTampering with the electronic system in-stallation can be dangerous and could resultin personal injury or death and/or enginedamage. It is very important to take theproper precautions with the electrical andelectronic system when charging the batter-ies, jump-starting or performing electricwelding on the vehicle. See the vehicle Op-erator’s Manual for correct procedures.

The Volvo D12 engine uses high voltageto the electronic unit injectors. DO NOTcome in contact with the unit injectorterminals while the engine is running.An electric shock can cause an involun-tary muscle spasm and cause balanceloss and falls leading to severe personalinjury or death.

This engine is equipped with monitoringfeatures that may cause reduced power orshutdown under certain conditions. Thepower output, monitoring and idling fea-tures can only be programmed and/orchanged with electronic service tools andpasswords.

Certain features, such as low oil pressure,high coolant temperature or low coolantlevel could cause the engine power and/orvehicle speed to be limited and the enginemay also shut down. The shutdown willtake approximately 30 seconds from thetime the warning feature is activated. Seethe vehicle Operator’s Manual for moreinformation.

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Speed Restrictive TiresWhen a truck is equipped with Speed Re-strictive Tires it is extremely important thetruck should not be operated in excess ofthe indicated speeds. If your truck isequipped with such tires, the speed restric-tions will be stated on the sidewall of thetires. The operator of this vehicle is urgedto check the tires of the truck to determineif there are any limitations.

Operating a vehicle equipped with SpeedRestrictive Tires in excess of their statedrating may result in tread separationand/or blowout resulting in the loss ofsteering control and possible crash. Seri-ous personal injury or death could occur.Always maintain proper air pressure andnever exceed the tire ratings.


Reporting Safety DefectsUSAThe National Highway Traffic Safety Ad-ministration (NHTSA) and Volvo TrucksNorth America should be informed imme-diately if you believe that the vehicle has adefect that could cause a crash, injury ordeath.

Contact NHTSA by calling the Auto SafetyHotline at 1 (800) 424–9393 (or 366–0123in the Washington, DC area) or by writingto: NHTSA, U. S. Department of Transport,Washington, DC 20590.

1 (800) 424-9393

CanadaRefer consumer complaints to Volvo TrucksCanada, Inc. or to the Transport Canada —Department of Public Complaints, Recallsand Investigations.

1 (905) 795-1555

MexicoVolvo Trucks of Mexico, S.A. de C.V.should be informed immediately if you be-lieve the vehicle has a defect that couldcause a crash, injury or death. ContactVolvo Trucks de Mexico by calling 91 (5)259–3011 or by writing to: Volvo Trucksde Mexico, S.A. de C.V., Prol. Paseo de laReforma 600, 1er. Piso — 121, Col. SantaFe Peña Blanca, C.P. 01210, México, D.F.

01 (800) 90 94 900

General Engine Design Information 21

Engine Overview D7

W2002703

1. Fuel filters (secondary)

2. Turbocharger

3. Exhaust pressure governor (EPG)

4. Coolant drain connection

5. Coolant filter

6. Electronic injection pump

7. Hand fuel primer pump

22 General Engine Design Information

W2003664

8. Engine electronic control unit(EECU)

9. Oil fill cap

10. Oil dipstick

11. By-pass oil filter

12. Full-flow oil filter

13. Starter motor


Engine Compartment Overview D7

W2002695

1. Electronic injection pump

2. Exhaust pressure governor (EPG)

3. Fuel filters (secondary)

4. Inlet from charge air cooler

5. Coolant surge tank

6. Fuel filter (primary)(location depends on model)

7. Oil fill cap(hidden from view)


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8. Engine air filter

9. Air filter restriction gauge

10. Intake air heater

11. Oil dipstick

12. Air compressor

13. Outlet from charge air cooler


Engine Overview, D12

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1. Oil Fill Cap

2. Starter Motor

3. Electronic Control Unit (ECU)

4. Fuel Filter (secondary)

5. Oil dipstick (Earlier model D12)


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9. Coolant Drain Connection

10. Exhaust Pressure Governor(EPG)

11. EPG Air Valve

12. Turbocharger

13. By-Pass Oil Filter

14. Full-Flow Oil Filters

15. Air Compressor

16. Coolant Filter

17. Coolant Radiator

18. Charge Air Cooler


Engine Compartment Overview, D12

W2003417

1. Oil Fill Cap

2. Intake Air Heater

3. Engine Electronic Control Unit(EECU)

4. Coolant Surge Tank

5. Outlet From Charge Air Cooler


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6. Engine Air Filter

7. Coolant Fill Cap

8. Radiator

9. Primary Fuel Filter

10. Oil Dip Stick (Latest modelD12)

11. Turbocharger (Hidden behindEngine Air Filter)


Engine Features

Feature Benefit

• VECTRO II - Volvo EngineElectronics System

• Engine Brake Control (D12)• Differentiated Speed Control• Road Speed Limiter• PTO Speed Setting• Cruise Control• Idle Speed Setting• Idle Timeout

• VECTRO II Diagnostics • Ease of Troubleshooting

• Air-to-Air Charge Air Cooler • Superior Fuel Economy• Peak Performance• Low Process Temperature

• Two-Piece Piston and OptimizedCompression Ratio (D12)

• Minimum White Smoke• Low Internal Friction

• Standard Exhaust Brake • Efficient Braking on Grades• Superior Temperature Control at Idle• Quick Warm-Up

• Optional Volvo Engine Brake (VEB)(only D12)

• Exceptional Engine Braking Even atLow Engine Speed

• Optional Pre-Heater Element • Excellent Startability to as Low as-15�F (-25�C)

• Minimum Smoke and Odor After Start• No Fuel Dilution of Oil in Cylinder

Due to Complete Combustion• Less Engine Wear

• Cylinder Liners with Plateau Honing • Optimized Oil Consumption

• Engine-Mounted Fan Ring • Efficient Cooling with Low ParasiticLosses

• Electronically Controlled Fuel Injection • Precise Control of Combustion• Centrally Located Vertical Unit

Injectors• Maximum Fuel Efficiency

• Engine-Driven Power Take-Off • Clutch Independent PTO


VECTRO II Customer Parameter Values, D7

Parameter DefaultValue

MinimumValue

MaximumValue

PTO:

• Maximum engine speed, r/min• Resume speed

2500800

Low IdleLow Idle

High IdleHigh Idle

Road Speed Limit (RSL):

• Value RSL (technical), mph (km/h)• Printout RSL value, mph (km/h)

87 (140)87 (140)

30 (48)30 (48)

87 (140)87 (140)

Cruise Control (CC):

• CC enable (yes/no)• Maximum Vehicle Speed, mph (km/h)• Minimum Vehicle Speed, mph (km/h)

Yes87 (140)30 (48)

-30 (48)30 (48)

-RSLRSL

Differentiated Speed Limiter:

• Yes/No• Transmission With Overdrive (yes/no)

NoNo

--

--

External Engine Protection:

• Yes/No Yes - -

Standstill Maximum Engine Speed:

• Maximum Engine Speed, r/min High Idle 2500 High Idle

NOTE! This parameter listing is not com-plete. Contact your Volvo Truck dealer fora complete listing.

Customer Parameters can be changed witha VCADS Pro tool, available at your VolvoTruck dealer.


VECTRO II Customer Parameter Values, D12

Parameter DefaultValue

MinimumValue

MaximumValue

PTO:

• Maximum engine speed, r/min• Resume speed

1200800

Low IdleLow Idle

High IdleHigh Idle

Road Speed Limit (RSL):

• Value RSL (technical), mph (km/h)• Printout RSL value, mph (km/h)

87 (140)87 (140)

30 (48)30 (48)

87 (140)87 (140)

Cruise Control (CC):

• CC enable (yes/no)• Maximum Vehicle Speed, mph (km/h)• Minimum Vehicle Speed, mph (km/h)

Yes87 (140)30 (48)

-30 (48)30 (48)

-RSLRSL

Differentiated Speed Limiter:

• Yes/No• Transmission with Overdrive (yes/no)

NoNo

--

--

Idle Timeout:

• Yes/No• Time Before Shutdown (if yes), minutes

No5

-1

-40

Standstill Maximum Engine Speed:

• Maximum Engine Speed, r/min High Idle 1200 High Idle

NOTE! This parameter listing is not com-plete. Contact your Volvo Truck dealer fora complete listing.

Customer Parameters can be changed witha VCADS Pro tool, available at your VolvoTruck dealer.


Engine Variants, D7

Power Output Options

D7C-275 D7C-300

Output, net1, @ 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 Net output according to ISO 1585 and SAE J1349.

Engine Standard Equipment• Air-to-air charge air cooler

• Primary fuel filter and Volvo spin-onsecondary fuel filters

• Exhaust pressure governor (EPG)

• Electronically controlled fuel injection

• One Volvo full-flow and one Volvo by-pass oil filters

• Electronic engine diagnostics system

• Intake air preheater element

• Thermostatically controlled fan

• 100 Ampere alternator

• Side mount oil fill tube (WX only)

• Base Warranty: 2 years or 250,000miles; parts and labor (For coveredcomponents, see the warranty certifi-cate)

Engine Optional Equipment• Engine block heater for coolant

• Engine oil pan heater

• Side-mounted oil fill tube (WG)

• Alternators from 85 to 145 Ampere


Engine Variants, D12

Power Output Options

D12C-345 D12C-385 D12C-425 D12C-465

Output, net1, @ 1700 r/min 345 hp(254 kW)

385 hp(283 kW)

425 hp(317 kW)

465 hp(338 kW)

Torque, net1, @1100 -1200r/min

1350 lb-ft(1830 Nm)

1450 lb-ft(1965 Nm)

1550 lb-ft(2100 Nm)

1650 lb-ft(2236Nm)

Governed speed 1900 r/min 1900 r/min 1900 r/min 1900r/min

1 Net output according to ISO 1585 and SAE J1349.

Engine Standard Equipment• Air-to-air charge air cooler

• Primary fuel filter and Volvo spin-onsecondary fuel filter

• Exhaust pressure governor (EPG)

• Electronically controlled fuel injection

• Double Volvo full-flow and one Volvoby-pass oil filters

• Thermostatically controlled oil cooler

• Electronically controlled unit injectors

• Overhead camshaft

• Electronic engine diagnostics system

• On/off fan clutch

• 110 Ampere alternator

• Base Warranty: 2 years or 250,000miles; parts and labor (For coveredcomponents, see the warranty certifi-cate)

Engine Optional Equipment• Volvo Engine Brake — 350 hp brak-

ing power @ 2 300 r/min.

• Engine direct-mounted PTO — outputup to 60 hp or 300 lb-ft

• Intake air preheater element

• Engine block heater for coolant

• Engine oil pan heater

• Side-mounted oil fill tube

• 85 or 135 Ampere alternator

• Thermostatically controlled fan


Engine Data

Fill in the blanks for future reference:

Vehicle Identification Number (VIN) [ ................................................................................ ]

Engine Model [ ..................................................................................................................... ]

Engine Serial Number [ ....................................................................................................... ]

Engine Power Output [ ......................................................................................................... ]

Engine Low Idle Speed [ ..................................................................................................... ]

Engine Full Load Speed [ .................................................................................................... ]

Engine Full Torque [ ............................................................................................................ ]

Primary Fuel Filter P/N [ ..................................................................................................... ]

Secondary Fuel Filter P/N [ ................................................................................................. ]

Oil Filter P/N, Full Flow [ ................................................................................................... ]

Oil Filter P/N, By-pass [ ...................................................................................................... ]

Air Cleaner Element P/N [ .................................................................................................. ]

Coolant Filter P/N [ .............................................................................................................. ]

Fan Drive Belt Set P/N [ ...................................................................................................... ]

Alternator Belt P/N [ ............................................................................................................ ]

Engine Storage 35

Engine StorageIf the vehicle should be parked for a period(over 30 days), make it is protected as fol-lows:

1 Drain the engine of its used oil.

2 Fill up to the proper level with oil ofthe recommended quality and viscos-ity.

3 Fill up the fuel tanks with the recom-mended grade of fuel.

4 Run the engine for two minutes around1000 r/min. Shut the engine down. Donot drain the oil after this run.

5 Check the engine air filter and, if nec-essary, change it.

6 Check the coolant for proper levels ofantifreeze and inhibitor (SCA) protec-tion. Service as necessary.

7 Clean the exterior of the engine.

8 Seal all engine openings using a wa-terproof, vaporproof and strong tape.

To return an engine preserved in this man-ner can be done in a short time by removingthe seals and checking all engine fluids:coolant, fuel, crankcase oil. Also check allother component fluid levels on the vehicle.

36 Engine Storage

Starting Engine After an Extended Shutdown


If an engine has been sitting unused formore than a week or if an oil change hasbeen performed, it is recommended that theoil pressure is established before startingthe engine. This can be done by crankingthe engine without fuel delivered to thecylinders. Let an experienced techniciancarry out the following:

1 Separate the in-line fuse feeding theengine electronic control unit. Thefuse is located in the battery box.

2 Use the starter to turn the engine overuntil the oil pressure registers on theoil gauge.

CAUTION

Do not crank the engine for morethan 30 seconds at a time; wait twominutes after each try to allow thestarter to cool. Failure to followthese instructions could causestarter damage.

3 Install the fuse.4 Start the engine.

NOTE! This procedure will load a fault inthe diagnostic message display but will notinterfere with running the engine.

W3002417

VN-series fuse location

Cooling System 37

General Coolant InformationGeneralDo not raise the engine hood or cab if yousee or hear steam or coolant escaping fromthe engine compartment. Wait until steamor coolant cannot be seen or heard beforeraising the hood or cab.

Do not remove the coolant fill cap if thecoolant in the surge tank is boiling. Also,do not remove the cap while the engine andradiator are still hot. Scalding fluid andsteam may be blown out under pressure ifthe cap is taken off too soon.

W2002056

WARNING

Hot engine! Keep yourself clear of allmoving parts or hot engine parts, ex-haust gases, and/or fluids. A hot engine,exhaust, and/or fluids can cause burns.

38 Cooling System

Many engine failures can be traced back toa problem in the cooling system. Alwaysmake sure that the coolant level is abovethe min. mark on the surge tank. If thecoolant level is allowed to go below thebottom of the tank, there is the risk of theengine shutting down. See the Operator’sManual for more information on the warn-ing functions. See page 118 or page 120 forinformation on how to change the coolant.

Risk of poisoning. Ethylene and propy-lene glycol are very toxic. To preventpersonal injury or death, do not drinkcoolant. Use proper eye and hand pro-tection when handling. Keep coolant orconcentrated antifreeze out of reachfrom children and animals.

NOTE! Always dispose of coolant accord-ing to Federal or local regulations. Take allused coolant to a recycling or waste collec-tion center.

W2002049

Cooling System 39

Recommended coolant mixture is a 50/50mixture of antifreeze and clean water.Never run the engine with only water. Re-gardless of the season, the coolant shouldalways contain at least 40 to 60 percentethylene glycol (antifreeze). The antifreezealso contains anti-corrosion agents that thecooling system needs to stay functional.

NOTE! Do not use a winterfront for thecooling system. See the Operator’s Manual,Engine Start and Operation, for more infor-mation.

NOTE! Do not mix regular and extendedlife antifreeze. This may result in reducedengine life.

Engine design requires the thermostat inthe engine during summer and winter. Cor-rect engine temperature should be aminimum of 165�F (75�C) with a properlyfunctioning thermostat.

WARNING

Under some conditions, the ethyleneglycol in antifreeze can be combustible.To help avoiding being burned whenadding coolant, do not spill coolant onthe exhaust system or engine parts thatmay be hot.

Do not add cold coolant to an overheatedengine because a cracked head and blockmay result.

W2003082

40 Cooling System

Keep the radiator (including charge aircooler) and the frontal area free from bugs,dirt, leaves, etc. (see page 123 for cleaninginformation). Always keep the coolant levelabove the min. mark on the coolant expan-sion tank.

Inspection of the whole cooling system isimportant. Check for swollen or deterio-rated heater and radiator hoses, loose hoseclamps and connections, and radiator leaks.

WARNING

Do not work near the fan with the en-gine running. The engine fan can engageat any time without warning. Anyonenear the fan when it turns on could beseriously injured. Before turning on theignition, be sure that no one is near thefan.

W2002049

Cooling System 41

W2002697

1. Thermostat Housing2. Radiator3. Surge Tank4. Coolant Cap

5. Level Sensor6. Heater Element7. Coolant Filter8. Coolant Pump

Risk of poisoning. Ethylene and propy-lene glycol are toxic. To preventpersonal injury or death, do not drinkcoolant. Use proper eye and hand pro-tection when handling. Keep coolant orconcentrated antifreeze out of reach ofchildren and animals.

WARNING

Never add coolant to a hot or overheatedengine. Engine damage can result, andscalding steam or liquid can cause seri-ous personal injury.

A well functioning and maintained coolingsystem is as important to the engine as per-forming regular oil changes or using goodfuel. To get the best result it is very impor-tant to use quality products and to servicethe system at the right intervals. Pleaseread this section carefully.

The cooling system consists of a liquid thatis pumped by a gear driven coolant pumpthat keeps the flow through the engine tothe radiator. The radiator gives off heat tothe air as it passes through and air flow ishelped by the engine fan. For a quickwarm-up of the engine, a thermostat regu-lates the flow of coolant.

42 Cooling System

Coolant is made up of a mixture of cleanwater and antifreeze. This mixture shouldnever be less than 40% antifreeze and 60%clean water or more than 60% antifreezeand 40% clean water. Mix the antifreeze/water mixture to the required concentrationbefore adding to the cooling system.

NOTE! Do not mix different products,such as regular antifreeze and extended lifeantifreeze.

NOTE! Volvo Trucks North America, Inc.does not recommend the use of antifreezebased on propylene glycol.

W2003082

Coolant, consisting of an antifreeze solu-tion in water, should be used year-round toprovide freeze and boil-over protection aswell as providing a stable environment forseals and hoses. The solution needs to betested for proper additive levels at regularintervals (see page 49 for testing SCA lev-els), unless extended life antifreeze is used.Adjust additive concentration if not at theproper levels.

NOTE! Do not use antifreeze formulatedfor automobile gasoline engines. Thesehave a very high silicate content that willclog the radiator and leave unwanted de-posits in the engine.

Cooling System 43

The main purpose of coolant is to transportheat from the hot parts of the engine to theradiator and to protect the cooling systemfrom corrosion.

In addition to this, the coolant must:

• Protect against pitting and cavitationerosion damage of the water pump andcylinder liners.

• Protect against freezing and boiling.• Prevent formation of scale, sludge de-

posits and clogging.• Be harmless to polymer materials and

sealings in the coolant system.• Maintain its liquid properties in cold

climates.

Coolant should consist of these three com-ponents:

• Clean water.• Additives.• Antifreeze (Glycol).

See the following pages for proper han-dling, mixtures and specifications.

44 Cooling System

Water Specification

CAUTION

Volvo Trucks North America, Inc. doesnot recommend using plain water in thecooling system. Water alone is corrosiveat engine operating temperatures anddoes not provide adequate boiling pro-tection. The water may cause corrosionand cavitation problems in engine andradiator, and the boiling point of thecoolant is lowered compared with an an-tifreeze/water mixture. The warranty isnot valid when using only water in thecooling system.

Use clean water in the coolant mixture. DONOT use hard tap water or salt softened tapwater in the cooling system. If clean wateris not available, using distilled water isideal. Water specification should be:

Parts perMillion

Grains perGallon

Chlorides, maximum 40 2.5

Sulfates, maximum 100 5.8

Silica, maximum 20 1.17

Iron, maximum 0.10 0.0058

Manganese, maximum 0.05 0.0029

Total dissolved solids, maximum 340 20

Total hardness, maximum 170 10

pH value 5.5 to 9

If you are not sure of the quality of the wa-ter in your area, contact your Volvo Truckdealer, your local water department, agri-cultural agent or an independent laboratoryto analyze the water.

Cooling System 45

AdditivesAdditives are part of most antifreeze andshould be tested for and added to allcoolant mixtures using normal antifreeze. Ifextended life coolant is used, the additivesare in the product when mixed. Both typesneed to have additives added to them aftera time.

Additives help prevent rust, scale and min-eral deposits from forming. Additives alsoprotect metals from corrosion, prevent wa-ter pump and cylinder liner cavitation andcontain anti-foaming agents. Additives aredepleted during normal engine operationand need to be replaced. For normalcoolant mixture, this means the addition ofSupplemental Coolant Additives (SCA) atany time the additive goes below the rec-ommended level. For extended life coolantmixture, this means an extender packageadded halfway through the coolant lifetime.

Nitrites or nitrite and molybdate additivesprotect the cylinder liner from cavitationerosion. Nitrites deplete over time, creatingthe need for SCA’s or extender. Othercoolant additives also deplete and need re-placement.

A very low concentration of additives inthe coolant will not provide the protectionrequired by the cooling system. A veryhigh concentration of additives in thecoolant can cause additives to solidify anddrop out of the solution, depositing insidethe cooling system or form a gel in the ra-diator. Deposits can be in the form ofsludge and scale. Deposits accumulate onhot engine surfaces, reducing the effective-ness of the cooling system or causing waterpump leaks.

46 Cooling System

AntifreezeGeneral

Risk of poisoning. Ethylene and propy-lene glycol are toxic. To preventpersonal injury or death, do not drinkcoolant. Use proper eye and hand pro-tection when handling. Keep coolant orconcentrated antifreeze out of reachfrom children and animals.

WARNING

Never add coolant to a hot or overheatedengine. Engine damage can result. Allowthe engine to cool first.

CAUTION

Use of recycled antifreeze or coolant byfiltration is not approved by VolvoTrucks North America, Inc. If the recy-cled antifreeze or coolant has beenpassed through a fractional distillation orsimilar process that has removed all haz-ardous and contaminating materials,including dissolved solids and acids, itwill produce a sufficient base antifreeze.Correctly inhibited to meet the ASTMD4985 standard, it can be regarded as anew coolant which is fully accepted.However, use of recycled antifreeze orcoolant by filtration may reduce enginelife.

Antifreeze additives not only protect thecooling system from freezing but alsoagainst corrosion and cylinder liner pitting.Antifreeze typically comes in one of twoglycol types, ethylene or propylene. Propy-lene antifreeze is NOT recommended foruse in a Volvo engine. There is also regularand extended life antifreeze. If the vehicleis delivered with extended life coolant,there is a label attached to the surge tank.

NOTE! Do not mix regular and extendedlife antifreeze. Do not use extended life an-tifreeze unless it is of a type approved bythe engine manufacturer.

Regardless of the type and make, accept-able antifreeze or premixed coolant mustmeet or exceed the standards ASTM D5345 and ASTM D 4985, and be formu-lated for heavy duty diesel engines.

W2002144

Cooling System 47

Antifreeze or premixed coolant meeting thestandards ASTM D 3306 or ASTM D 4656are primarily for automotive gasoline en-gines, containing high levels of silicate, andare unacceptable for heavy duty diesel en-gines.

Recommended antifreeze meeting theASTM D 4985 standard is a low silicateethylene glycol based antifreeze for heavyduty diesel engines. Standard antifreeze re-quires an initial charge of supplementcoolant additives (SCA) when filling newcoolant. Extended life antifreeze does notneed an initial charge.

NOTE! ASTM D 4985 requires the use ofSCA to be added to the coolant to bring itup to the recommended SCA level whenthe coolant is initially filled or replaced.

Water and antifreeze should generally befilled as a 50/50 mixture. The mixtureshould never be less than 40% antifreezeand 60% clean water or more than 60% an-tifreeze and 40% clean water. Mix theantifreeze/water to the required concentra-tion before adding to the cooling system.The following table gives approximatefreezing protection for certain mixtures.

Freeze ProtectionDown To:

Percentage of An-tifreeze in Mixture

-13 �F (-25 �C) 40 %

-22 �F (-30 �C) 46 %

-36 �F (-38 �C) 54 %

-51 �F (-46 �C) 60 %

NOTE! 60% antifreeze in the mixture givesmaximal freeze protection. To increase theantifreeze content beyond that will only de-crease the freeze protection.

W2003082

48 Cooling System

Regular Coolant Change IntervalReplace the coolant every 250,000 miles(400,000 km), 4,000 hours or every twoyears, whichever comes first.

Coolant SCA level must be tested at leasttwice per year or whenever coolant lossoccurs. For maximum coolant system effi-ciency, test the system every 25,000 to30,000 miles (40,000 to 56,000 km) de-pending on engine oil change interval orevery 1,000 hours or maximum every 6months (whichever comes first).

The SCA level must be between 1.5 (Cum-mins: 1.2) and 3.0 SCA units per gallon(0.4 [Cummins: 0.3] and 0.8 SCA units perliter) of coolant.


Coolant Filter Change IntervalsThe charged coolant filter contains 8 unitsof SCA that are released slowly over timeto maintain the recommended level duringoperation. Change coolant filter after thefirst 30 days or 6,000 miles (10,000 km).Thereafter:

Change the coolant filter at every other oilchange when running 10,000 to 15,000mile (16,000 to 24,000 km) intervals (everyoil change when running 25,000 mile inter-vals on a D12). If the SCA level testsabove 3.0, DO NOT replace the filter.When testing indicates that the SCA levelhas dropped below 1.5 units per US gallon(0.4 units per liter) start changing the filterwith the oil changes again.

NOTE! Test the SCA level every 6 months.

WARNING

Keep yourself clear of all hot engineparts and/or fluids. A hot engine and/orfluids can cause serious burns.

Cooling System 49

Standard Antifreeze Testing

GeneralCoolant SCA level must be tested at leasttwice per year and whenever coolant lossoccurs. For maximum coolant system effi-ciency, test the system every 25,000 to30,000 miles (40,000 to 56,000 km), de-pending on the oil change interval, or every1,000 hours or every 6 months (whichevercomes first).

Use liquid SCA and pre-charged coolantfilters to maintain a 1.5 to 3.0 SCA unitsper gallon (0.4 to 0.8 units per liter) con-centration in the coolant.

W2001081

Depending on the make of antifreeze orpremixed coolant, SCAs are added or haveto be added to the system after replace-ment. The SCA level will deplete over timeso it is important that the SCA level istested regularly and maintained. The Volvopre-charged filter is designed to slowlyrelease the SCA to help maintain the rec-ommended level during operation.

NOTE! Only change the filter after testingshows depleted SCA in the cooling system.Do not exceed the 3.0 units per gallon(0.8 units per liter) concentration. ExcessiveSCA concentration can form deposits on thehigher temperature surfaces of the coolingsystem, reducing the engine’s heat transfercharacteristics. Reduced heat transfer couldcause cracking of the cylinder head andother high temperature components. Exces-sive SCA concentration can also result inradiator tube blockage, overheating and/oraccelerated water pump seal wear.

W2001082

Coolant filter

50 Cooling System

Testing ProcedureRun the engine to operating temperature.After the engine has reached operating tem-perature, move the heater controls (on dashand in sleeper) to full heat and run the en-gine for 10 more minutes.

WARNING


Shut off the engine and allow it to cool.Test the coolant with the test kit. Dependingon the concentration of SCA in the coolant:

• If the SCA concentration is below 1.5units per gallon (0.4 units per liter),replace the coolant filter and calculatethe required units of SCA to reach thedesired SCA level. See example.

• Between 1.5 and 3.0 units per gallon(0.4 and 0.8 units per liter), replacethe coolant filter, P/N 3945411.

• Above 3.0 units per gallon (0.8 unitsper liter). Do not replace the coolantfilter until further testing at the nextoil change indicates that the level hasdropped below 2.3 units per gallon(0.6 units per liter).

CAUTION

SCA levels deplete during normal opera-tion and when coolant is added becauseof low coolant level. SCA levels shouldbe maintained at the middle of the rec-ommended interval.Unit per gallon:1.5 LOW - 2.3 MID - 3.0 HIGHUnits per liter:0.4 LOW - 0.6 MID - 0.8 HIGH

EXAMPLE

Step 1 Desired

SCA level

2.3 units

per gallon

recom-

mended

level 1.5-

3.0 units

per gallon

Subtract: -

Coolant

test results

1.5 units

per gallon

=

Required

SCA per

gallon

increase

0.8 units

per gallon

Step 2

Cooling

system

capacity

13 US

gallons

Use actual

system

capacity

Multiply

by:x

Required

SCA per

gallon

increase

0.8 units

per gallon

=

Total SCA

units

required

10.4 units

(11 units)

round up

to nearest

whole

number

FIND-

INGS

Use one (8 unit) filter, P/N 3945411 and

3 units liquid SCA

See “Cooling System Capacity*” page163 for system quantities.

Cooling System 51

Changing from Regular to Extended Life CoolantDrain the system of old coolant and dis-pose of properly. The cooling systemshould be flushed with clean water. If sig-nificant deposits are visible, use a reputablecommercial cooling system flush designedfor heavy duty diesel engines. For specificinformation over draining and flushing, Seepage 118 for D7 and page 120 for D12 en-gines.

1

WARNING

Do not remove the cap to thecoolant surge tank while the engineand radiator are still hot. Scaldingfluid and/or steam may be blownout under pressure if the cap istaken off too soon.

Drain the coolant into a suitablecontainer. Make sure the heater tem-perature controls and valves are open.

NOTE! Always dispose of coolant ac-cording to Federal or local regulations.Take all used coolant to a recycling orwaste collection center.

2 Flush the system with clean water toremove any settled debris.

NOTE! Keep the water pressure lowso as not to damage the tubes of theradiator.

3 Use a reputable cleaner to clean thecooling system. Follow the recommen-dations that come with the cleaner.

52 Cooling System

4 Drain the cleaner and flush the coolingsystem with clean water.

5 Fill the cooling system with clean wa-ter and operate the engine until thecoolant temperature has reached 120�

to 150�F (50� to 65�C).

6 Drain the water and flush the coolingsystem with clean water.

7 Again, fill the cooling system withclean water and operate the engine un-til the coolant temperature has reached120� to 150�F (50� to 65�C).

8 Drain the water and flush the coolingsystem with clean water.

9 Fill the cooling system with pre-mixedExtended Life Coolant. Check thespecifications section for refill quantity.

10 Attach label P/N 3969338to thecoolant surge tank to indicate that thesystem is now filled with ExtendedLife Coolant. The label can be or-dered from your Volvo Truck dealerspare parts department.

NOTE! When changing over from standardto extended life antifreeze, tighten all hoseclamps and fasteners in the cooling system.Extended life coolant tends to leach out de-posited silicate and leaks may appear.

W2002144

Cooling System 53

Extended Life Coolant Change IntervalReplace coolant every 300,000 miles(480,000 km), 6,000 hours or every fouryears, whichever comes first.

A one-time extender package must beadded to the cooling system after 150,000miles (240,000 km), 3,000 hours or twoyears, whichever comes first.

NOTE! Do not add supplement coolantadditives (SCA) to extended life coolant.

CAUTION

Extended life coolant will test as out ofadditives (SCA), but SCA should not beadded. Shortened engine life may be theresult of adding SCA.

Should the system become contaminatedwith regular coolant exceeding 10% of thesystem’s total capacity or if SCA is addedto the system, either drain the system andrefill with new extended life coolant ormaintain the system as for regular coolant.Continue treating with SCA and change thecoolant at the intervals recommended forregular coolant.

Coolant FilterDo not use a filter that contains SCA. In-stead use a bypass canister or “empty”filter. Replace the “empty” filter every125,000 miles (200,000 km) or 2,500 h or12 months, whichever comes first, to pre-vent external rust damage to the filterwalls.

WARNING


54 Fuel System

Fuel Safety Reminders

WARNING

The vapors from hot diesel fuel areflammable at high temperature. To avoidpossible personal injury and/or propertydamage from fire, stop the engine imme-diately if a fuel leak is detected. This isespecially important if the fuel is drip-ping onto hot surfaces.

To avoid potential fire hazard, do notservice any part of the fuel system whilesmoking or in the presence of flames,sparks or hot surfaces, or when workingon an operating engine. Failure to followthese precautions can result in fire, per-sonal injury or death. To guard againstburns, always wear adequate protectiveclothing (face shield, heavy gloves andapron, etc.) when working on a hot en-gine.

A diesel engine will operate on any fuelwhich enters the cylinder, whether it isfrom the injectors or from the air intakesystem. Therefore, if any solvent is usedto flush out the air cleaner element, theengine may overspeed during startup.Engine damage, severe injury and/ordeath from burns or explosion may oc-cur.

Do not mix gasoline or alcohol withdiesel fuel. This mixture can cause anexplosion and result in severe personalinjury or death.

Do not remove the fuel tank cap near anopen flame. Diesel fumes are com-bustible and can cause an explosion offire resulting in severe personal injury ordeath.

WARNING

Do not store fuel containers in the vehi-cle. They may leak, explode and causeor feed a fire. Empty or full, theypresent a hazard that may lead to burnsin the event of a fire.

WARNING

To prevent buildup of potentially volatilevapors from hot fuel, keep the enginearea well ventilated during operation.

Fuel System 55

Diesel Fuel Specification

QualityFuel quality is an important factor in ob-taining satisfactory engine performance,long engine life and acceptable exhaustemission levels. Volvo engines are designedto operate on most diesel fuels commer-cially available today. Volvo Trucks NorthAmerica, Inc. recommends the use of dieseloil fuel which meets the specificationASTM D975 (grades No. 2–D andNo. 1–D).

NOTE! The use of lighter fuels (gradeNo. 1–D) can reduce fuel economy.

The fuels used must be clean, completelydistilled, stable and non-corrosive. Alwaystry to keep the fuel tank full. Do not put al-cohol into the fuel tank. Fill the tank aftercompleting driving for the day.

NOTE! When draining the fuel tank, col-lect the waste in a fuelproof container. Takethe drained fuel and water to a recycle orwaste management center.

Open the drain at the bottom of the fueltank approximately every 30,000 miles(50,000 km) or 300 hours, to drain off anywater and/or sediment.

Yearly or at 120,000 miles (200,000 km),tighten all fuel tank mountings and brack-ets. Check all hoses, pipes and lines to andfrom the fuel tank. At the same time, in-spect tank and connections for any signs ofleakage. Make sure that hoses and lines arenot resting on or touching shafts, couplings,hot surfaces or sharp areas. Since all ma-chinery vibrates and moves to a certainextent, clamps and ties can fatigue withage. Inspect fasteners frequently andtighten or replace them as necessary.

56 Fuel System

Fuel FiltersNOTE! When draining the primary fuelfilter, collect the waste in a fuelproof con-tainer. Always dispose of coolant accordingto Federal or local regulations. Take thedrained fuel and water to a recycle or wastemanagement center.

For fuel filter change intervals see “FuelFilter Change Intervals” page 124.

For other engines, the engine manufacturersrecommend changing the fuel filter at everyoil change. For bleeding the fuel system,see page 130 for D12 and page 132 for D7engines or the engine manufacturer’s opera-tor’s manual for other engines.

W2001067

Fuel Sulfur ContentFuel sold after 1994 for highway use canonly contain a maximum sulfur content of0.05% by weight. This was done to reduceparticle emissions in the exhaust.

The sulfur content for off-highway use con-tinues to be specified at a maximum of0.5% by weight. The use of a fuel contain-ing 0.5% or higher level of sulfur,necessitates more frequent engine oilchanges because of sulfur deposits andhigher corrosion risk. If using fuels withhigh sulfur content, the oil change intervalsmust be cut in half. See “Sulfur Level andTBN” page 72 for more information.

NOTE! The use of low sulfur diesel oilfuel does not permit extension of engine oilchange intervals or oil filter changes.

Fuel System 57

Cetane NumberDirect injected diesel engines require aminimum cetane number of 40 under nor-mal starting conditions. Fuel with a highercetane value may be required for high alti-tude or cold weather operation.

FiltrationFuel should be clean and free of contami-nation. Clean fuels should have no morethan 0.1% of sediment and water.

If fuel is stored on site, make sure that:

• Keep storage tank covered to preventwater entry.

• Do not use a tank made of galvanizedmetal or any galvanized piping fordiesel oil storage. Diesel will reactwith the zinc, forming solids that canclog fuel filters and cause engine dam-age.

• Fuel stored for a long time may oxi-dize and form solids, causing filteringproblems.

• Keep the area around the fill capclean. Tilt the tank slightly toward thedrainplug area so water and sedimentcan be easily drained.

Generally, fuel contamination occurs as theresult of improper fuel handling. The mostcommon types of contamination are water,dirt and microbial growth (“black slime”).The formation of varnishes and gums result-ing from poor fuel stability or long storage(“stale fuel”) also affects fuel quality. Thebest treatment for contamination is preven-tion by maintaining a clean storage systemand choosing a reputable fuel supplier.

58 Fuel System

Fuel Pour PointFuel pour point should be at least 10�F(6�C) lower than the lowest ambient tem-perature at which the engine must start andoperate. Lower pour points of diesel fuelgrade No. 1–D may be necessary in ex-tremely cold weather.

Fuel Cloud PointThe cloud point should be below the lowestambient temperature at which the enginemust start and operate, to prevent the fuelfilter elements from plugging with waxcrystals.

Fuel ViscosityFuel viscosity must be kept above 1.4 cStat 100�F (38�C) to provide adequate fuelsystem lubrication. The viscosity also hasan effect on the atomization of the fuelwhen it is injected into the cylinders.

Fuel System 59

Fuel Additives

GeneralFuel additives are generally not recom-mended or needed for fuels listed earlier.Cetane improvers can be used as necessary.Biocides may be needed to eliminate mi-croorganism growth in storage tanks. Incold conditions, treatment for water in thevehicle tanks may also be necessary.

Consult your fuel supplier about the use ofadditives to prevent incompatibility amongadditives already in the fuel and the addi-tives to be used.

Supplemental Fuel Enhancers

CAUTION

Supplemental additives are not recom-mended because of a high risk ofinjection system problems or enginedamage.

There are many aftermarket products avail-able today which are intended to be addedby the customer. They generally increaseoperating cost without providing benefits.Included are a variety of independentlymarketed products which claim to be:

• Cetane improvers

• Emission control additives

• Detergents

• Combustion improvers

• Smoke suppressants

• Cold weather flow improvers

60 Fuel System

NOTE! Repair expenses resulting frommalfunctions in the fuel system or with en-gine components when fuel enhancers havebeen used are not covered under warranty.

Some fuel additives can be used to providetemporary relief but they do not replacegood fuel handling practices. These prod-ucts can be used:

• Isopropyl Alcohol — Use 1 pint per125 gallons (1/2 liter per 500 liters) offuel for winter freeze-up protection.

• Biocide — For treatment of microbegrowth or “black slime.” Follow man-ufacturer’s instruction for treatment.

Fuel System 61

Prohibited AdditivesThe following additives are specificallyNOT allowed and must NOT be mixed inwith the vehicle diesel fuel:

Used Lubricating Oil:Volvo Trucks North America, Inc. doesnot recommend the use of any type ofused lubricating oil as an extender inthe diesel fuel. Used lubrication oilcontains solids and acids from thecombustion process that can severelycorrode parts of the injection sys-tem, resulting in reduced power andhigher maintenance cost over time.

Gasoline:

Adding gasoline to diesel fuel will re-duce the cetane number and increasecombustion temperature. If a tank con-tains a diesel fuel/gasoline mixture, itshould be drained and cleaned as soonas possible.

62 Fuel System

Alternative FuelsAlternative fuels can be of several differenttypes. There are vegetable based fuels, avia-tion fuel and recycled petroleum based fuelsthat are used in combustion engines. Thesein general are not compatible with modernheavy duty over-the-road vehicle engines.

The use of unauthorized fuels may compro-mise the levels of pollutants in the exhaustto the point where the engine does not meetthe emission requirements. This wouldmake the vehicle illegal to drive on publicroads.

DO NOT use any kind of alternative fuelunless specifically authorized by VolvoTrucks North America, Inc.

Oil System 63

Engine OilGeneralKeep the engine oil at the proper level andchange it at the recommended intervals. Al-ways replace the oil filters at the same timeas when the oil is changed.

Always follow the oil change intervals anduse the oil types that are recommended bythe engine manufacturers. Oil change inter-vals for Volvo engines are found on page65. Viscosity and capacity tables can befound beginning on page 161. Other enginemanufacturers have different policiesregarding their products and should be con-sulted if a different change interval isdesired. Contact your Volvo Truck dealerfor more information.

For information on synthetic oil, see page70.

W1000077

NOTE! Always dispose of oil according toFederal or local regulations. Used oildisposed of in nature or waterways contam-inates our drinking water and kills wildlife.Take all used oil to a recycling or wastecollection center.

64 Oil System

Oil QualityVolvo Trucks North America, Inc. recog-nizes and recommends engine oils thatmeet or exceed the standards given byAmerican Petroleum Institute (API) for theoil classifications listed in this manual.Only oils licensed to carry the API symbolshould be used. Lubricants meeting APIstandards have provided maximum enginelife when used together with the recom-mended oil and oil filter change intervals.

Engines meeting the 2000 emissions re-quirements operate under higher sootloading conditions than previous engines.This has led Volvo to require a highergrade oil that meets both API CH-4 andVDS-2 quality standards for model year2000 Volvo engines. This type oil is re-quired for normal oil intervals.

Normal grade engine oils for all enginesin vehicles produced by Volvo TrucksNorth America, Inc. must meet or exceedthe API classifications CG-4 or CH-4.Also, Volvo has a specification calledVolvo Drain Specification (VDS) forVolvo engines. These types of oil necessi-tate more frequent oil changes (shorterintervals).

See page 65 for interval recommendationsfor Volvo engines. See other enginemanufacturer’s Operator’s Manuals for in-formation on when and how to change theoil for those engines.

Oils that meet both API CH-4 and VDS-2are required for model year 2000 Volvo en-gines with normal oil drain intervals. Mostmajor oil companies have oils that meetthese specifications. A list of approved oilscan be found in Service Bulletin 175–001.

W1000147

Typical API Symbol

CAUTION

Extra oil additives must not under anycircumstances be added to any engineoil used. Additives such as break-in oils,top oils, graphites and friction reducingliquids are not necessary and may evenharm the engine.

Oil System 65

Oil Change IntervalsThe length of time an engine is operatedbefore an oil change depends on the qualityof oil used, the type of fuel used, engine oilconsumption, vehicle application, level ofdust in the air, etc. The change intervalsgiven in this manual are maximum inter-vals. If the vehicle is operating inheavy-duty operation, dusty or off-roadconditions, using high sulfur fuels, etc., ad-just the intervals down for more frequentoil changes.

NOTE! Oil filters should always bechanged when changing oil.

Oil FiltersAlways change oil filters when changingthe oil. There may be two or three filters onthe engine, one of which is a bypass filter.This should be changed at the same time asthe regular full-flow filter(s).

CAUTION

Use only the engine manufacturer’s oilfilter for replacement. Use of an oil filterthat does not meet specification couldresult in severe damage to bearings,crankshaft, etc. as a result of unfilteredoil entering the lubrication system.

W2003173

D12 oil filters

66 Oil System

Oil Change Intervals, Volvo D7 EngineFirst oil change should be done at max.10,000 km (6,000 miles).

There are different oil change intervals forthe D7 engine, depending on which oilquality is used. Always use the correct oilquality for your application and distancedriven.

For example, in longhaul transport (>7mpg; <45,000 lb), oil changes can be doneevery 15,000 miles (24,000 km) if the oilquality meets or exceeds both API CH-4and VDS-2 quality standards. If the oildoes not meet both these requirements, oilchange intervals must be 7,500 miles(12,000 km). See Service Bulletin 175–001.

Volvo Trucks North America, Inc. does notissue a list of approved oils and oil compa-nies for standard oil that is defined by theAPI classifications. For oils that meet bothAPI CH-4 and VDS-2, which are requiredfor model year 2000 Volvo engines, there isa list that is periodically updated. For thecomplete list, see your Volvo Truck dealer.The list is contained in Technical ServiceInformation, TSI 175–001.

Depending on the seasonal temperaturechanges, select the correct viscosity of theoil. See page 71 for more information overoil viscosity.

Engines meeting the 2000 emissions requirements operate under higher soot loading con-ditions than previous engines. This has led Volvo to require an oil that meets both APICH-4 and VDS-2 quality standards for model year 2000 Volvo engines. 1999, and earlierengines, also work better with a CH-4 andVDS-2 oil, but it is not required.

Oil System 67

Type ofOperation

• Average fuelconsumption isunder 6.0 milesper gallon (over4.0 liters per 10km)

• Gross combinedweight (GCW)is greater than60,000 lb(27,000 kg)

• Idle time is 40%or higher

• Vehicle operatesoff road or industy areas

• Vehicle operatesin inner city de-livery

• Average fuel con-sumption is over6.0 miles per gal-lon (under 4.0liters per 10 km)

• Gross combinedweight (GCW) isless than60,000 lb(27,000 kg)

• Vehicle operatesin regional distri-bution

• Average fuelconsumption isover 7.0 milesper gallon (un-der 3.5 litersper 10 km)

• Gross combinedweight (GCW)is less than45,000 lb(20,000 kg)

• On highway op-eration only

Model Year 2000 (from engine serial No. 127058)Higher Oil Qualities

Oil Quality VDS-2 plus CH-4 VDS-2 plus CH-4 VDS-2 plus CH-4

Mileage*...................

Months* ....Hours* ......Fuel Usage*...................

10,000 miles(16,000 km)42501,500 gallons(5,700 liters)



Normal Oil Qualities

Oil Quality CG-4, CH-4 or VDS CG-4, CH-4 or VDS CG-4, CH-4 or VDS

Mileage*...................


5,000 miles(8,000 km)4125800 gallons(2,900 liters)

6,000 miles(10,000 km)4150900 gallons(3,400 liters)


* Whichever comes first

68 Oil System

Oil Change Intervals, Volvo D12 EngineFirst oil change should be done at max.10,000 km (6,000 miles).

There are different oil change intervals forthe D12 engine, depending on which oilquality is used. Always use the correct oilquality for your application and distancedriven.

For example, in longhaul transport (>6.5mpg; <80,000 lb), oil changes can be doneevery 25,000 miles (40,000 km) if the oilquality meets or exceeds both API CH-4and VDS-2 quality standards. If the oildoes not meet these requirements, oilchange intervals must be 19,000 miles(30,000 km). See Service Bulletin 175–001.

Volvo Trucks North America, Inc. does notissue a list of approved oils and oil compa-nies for standard oil that is defined by theAPI classifications. For oils that meet bothAPI CH-4 and VDS-2, which are requiredfor model year 2000 Volvo engines (fornormal drain intervals), there is a list that isperiodically updated. For the complete list,see your Volvo Truck dealer. The list iscontained in Technical Service Information,TSI 175–001.

Depending on the seasonal temperaturechanges, select the correct viscosity of theoil. See page 71 for more information overoil viscosity.

Engines meeting the 2000 emissions requirements operate under higher soot loading con-ditions than previous engines. This has led Volvo to require an oil that meets both APICH-4 and VDS-2 quality standards for model year 2000 Volvo engines. 1999 and earlierengines also work better with a CH-4 andVDS-2 oil, but it is not required.

Oil System 69

Type ofOperation

• Average fuelconsumption isunder 5.0 milesper gallon (over4.7 liters per 10km)

• Gross combinedweight (GCW)is greater than100,000 lb(45,000 kg)

• Idle time is 40%or higher

• Vehicle operatesoff road or industy areas

• Vehicle operatesin inner city de-livery

• Average fuelconsumption isbetween 5.0 and6.5 miles per gal-lon (between 4.7and 3.6 liters per10 km)

• Gross combinedweight (GCW) isless than100,000 lb(45,000 kg)

• Vehicle operatesin regional distri-bution

• Average fuelconsumption isover 6.5 milesper gallon (un-der 3.6 litersper 10 km)

• Gross combinedweight (GCW)is less than80,000 lb(36,000 kg)

• On highway op-eration only

Model Year 2000 (from serial # 172660)Higher Oil Qualities

Oil Quality VDS-2 plus CH-4 VDS-2 plus CH-4 VDS-2 plus CH-4

Mileage*...................





Normal Oil Qualities

Oil Quality CG-4, CH-4 or VDS CG-4, CH-4 or VDS CG-4, CH-4 or VDS

Mileage*...................





* Whichever comes first

70 Oil System

Synthetic LubricantsSynthetic oils are offered as an alternativeto the traditional, petroleum based oils forengines. These oils may be used in Volvoengines, provided they meet the quality lev-els specified on the previous pages, that is:API CG-4, CH-4, VDS or VDS-2.

Product information about synthetic oilshould be reviewed carefully. Their usedoes not permit an extension on recom-mended oil change intervals.

The ability to protect the engine is better insome ways compared with petroleum basedoils but its lifetime in the engine is thesame. This is because of the combustionby-products that contaminate the oil. Thesecontaminates will make the change inter-vals the same for petroleum based oils.

CAUTION

The use of synthetic oils does not permitan extension of the recommended oilchange intervals.

Synthetic oils offer improved low tempera-ture flow properties and high temperatureoxidation resistance. They are generallymore costly than petroleum based oils.However, in extreme driving conditions,that is, in extreme cold or in desert opera-tion, a synthetic oil may be the only choicefor the application (see next page aboutviscosity).

Oil System 71

Oil ViscosityThe viscosity grade defines the thickness ofthe oil. The oil must be thin enough at lowtemperatures for easy cold starts and thickenough to protect at high temperatures. Anoil is not fully defined until both the APIquality classification and the viscositygrade are specified.

Choose the viscosity grade for the typicalambient temperature for the application.Multigrade oils have a broad range that suitoperation in changing temperature.

Volvo Trucks North America, Inc. recom-mends the viscosities shown in theviscosity/temperature table for Volvo en-gines. See page 162 for vendor engines.Choosing an oil with a lower viscosity canhelp improve the fuel economy. However, ifthis is done, make sure the upper tempera-ture limit is not exceeded. Also, with lowviscosity oil, oil consumption can increase.

CAUTION

Extra oil additives must not under anycircumstances be added to any engineoil used. Additives such as break-in oils,top oils, graphites and friction reducingliquids are not necessary and may evenharm the engine.

W1000144

72 Oil System

Sulfur Level and TBNOils are available with different levels ofTotal Base Number (TBN) to counteracthigh sulfur levels in fuel. TBN measures anoil’s alkalinity and ability to neutralizeacid. Normally, the higher the fuel sulfur,the higher the TBN is needed. When USFederal fuel is used (sulfur less than0.05%), a minimum TBN of 5 is highlyrecommended.

Sulfur creates highly acidic pollutants inthe oil that break down the additives at ahigher rate. The sulfur content in low-sulfurfuel has been regulated to a maximum of0.05% by weight for No. 2–D diesel fuel.For fuels that have a sulfur content of 0.5%by weight and above, Volvo Trucks NorthAmerica, Inc. recommends that oil changeintervals are cut in half so a shortermileage is run between oil changes.

Oil Additives

CAUTION

Extra oil additives must not under anycircumstances be added to any oil used.A shortened engine life may be the re-sult.

Using oils to the quality standards recom-mended in this manual makes the use ofextra oil additives unnecessary, as these oilsalready contain a balanced treatment of ad-ditives. The use of extra oil additives suchas break-in oils, top oils, graphites and fric-tion reducing compounds are not necessaryand can even be harmful to the engine.

Oil System 73

Oil ConsumptionCheck the oil level daily with the enginestopped. If the engine has just been stoppedand it is warm, wait approximately fiveminutes to allow the oil to drain back to theoil pan before checking. Add oil as neces-sary.

NOTE! Do not overfill. Oil may be blownout through the crankcase breather tube ifthe level is too high.

All diesel engines are designed to use someoil, so it is normal to add oil periodically.An engine used in heavy duty operation willuse more oil than one in normal operation.

Owners often ask what is considered“normal” oil consumption. This is all de-pendent on the operation of the engine. Justas one engine in a heavy operation may getonly 5 mpg fuel consumption and anothergets over 8 mpg, the oil consumption willvary in different applications.

To determine “normal” oil consumption, itis therefore important to establish what isnormal for your engine in your application.Establish a record of oil usage and comparewith other vehicles in your fleet. There aretwo methods that are frequently used:

• Miles per quart of oil. Simple way toestablish a history of the consumption.Useful as a comparison to others onlywhen vehicle and engine is comparedto an identical vehicle and engine un-der identical operating conditions.

• Amount of oil used per amount of fuelused (oil consumption relative to fuelconsumption). Better way to relate theoil usage to the actual work of the en-gine. Also only useful in comparisonwhen compared under identicalconditions.

74 Oil System

Oil SamplingGeneralOil sampling is a good tool for determiningthe condition of the engine. The oil sam-ples are taken regularly over the life of theengine and establish a history of each spe-cific engine. The sampling results “paint apicture” of normal wear. When resultsoccur that are outside of the normal, it indi-cates that something is happening thatneeds investigating.

It is important to do regular sampling.One sample or irregular sampling willnot give any meaningful information.

Taking Samples

WARNING

Keep yourself clear of all hot engineparts and/or fluids. A hot engine and/orcan cause serious burns.

Samples should be taken when the oil iswarm and well mixed to be certain that thesample is representative of all the oil in theengine. Samples can be taken by having asampling valve installed on the engine orsampling through the oil dipstick tube.

Follow the instructions in the samplingpackage closely. A contaminated or notrepresentative sample will give false infor-mation of the health of the engine.

NOTE! Oil sample values can changeslightly from one engine to another, even ifthey are of the same model and manufac-turer. Base the decisions from regularsampling. Also note that repair work donewill often give a change in readings untilnew parts are worn in.

Oil System 75

Sampling ExamplesA new engine has a tendency to indicatehigh iron (Fe), lead (Pb) and copper (Cu)content during breaking in. Any left-overparticles from the manufacturing process(foundry sand, machining filings, etc.) in-crease wear at this stage. Wear at this pointshould not cause any alarm as higher wearparticle values nearly always show up dur-ing the breaking in period. Wait to seewhether the second and third oil analysesgive any indication that the particle levelshave changed to any extent.

76 Oil System

Wear ParticlesThe analysis values used for comparisonwith each other must always come from thesame engine. The results must be evaluatedwith the knowledge of where the particlesoriginate from. The particle level (ppm) de-pends on:

— Oil and filter system total volume— Oil volume when taking sample— Oil consumption— Driving conditions, fuel consumption— Time between oil changes

WearParticles:

Cause/Origin Normal Levels(ppm)

Fe - Iron Crankshaft, liners, camshaft, tappet, valve guides <100

Pb - Lead Big end and main crankshaft bearing shells <20

Cu - Copper Big end and main crankshaft bearing shells <20

Sn - Tin Surface layer of sliding bearings <20

Cr - Chrome Piston rings, valve rod <10

Al - Aluminum Pistons <10

Ni - Nickel Layer between the surface and copper layers on asliding bearing.

<5

Si - Silicon Sand, dirt, etc. <20

Insolubles Carbonized oil, combustion particles, soot <1.8%(by weight)

Water Coolant liquid, condensation water <0.1%(by weight)

Fuel Dilution Incomplete combustion <3.0%(by weight)

Antifreeze - Gly-col

High levels of sodium and boron indicate coolantleak

Should notoccur

Total Base Num-ber (TBN)1

TBN shows the remaining alkalines used for acidneutralization

>4.0

> = more than; < = less than

1 According to ASTM D2896

Oil System 77

RecommendationsTo get the best service life out of the en-gine, use oil sampling in addition to regularmaintenance. Oil analysis should only besupplementary to maintenance.In themaintenance program, always:

• Select high quality oils.

• Follow the oil change interval recom-mendations.

It is not recommended to disassemble anengine simply on the basis of the oil analy-sis values. Instead, use the values as anindicator that something unusual is happen-ing. Combine the oil analysis with otherdiagnostic methods to further confirm whatis happening.

For more information about oil intervalsand oil sampling evaluation, it is availablein the Technical Service Information, group175–001, at your Volvo Trucks dealer.

78 Short-Haul Service Schedule for VN-Series

General and Check-Charts

Short-Haul Service is defined here for vehicles that typically travel an annualdistance of maximum 50,000 miles (80,000 km) or less and operate undernormal conditions. This include applications that travel primarily on freewayswith little stop-and-go driving. Typical applications include: city delivery, localtransport with occasional freeway travel and a majority of stop-and-go driving.

The service categories show maximum allowable intervals. It is very importantto tailor the service to the actual application. Adjust the recommended serviceintervals to your operation.

Intercity Delivery

Moving different types of freight inmedium mileage operations between10,000 and 50,000 miles (15,000 and80,000 km) per year. Operation should beon road surfaces of good to excellent con-crete or asphalt. Greater than 20 milesbetween starting and stopping.

Vehicle types are: 4x2 tractor-trailer combi-nations and straight trucks.

Short-Haul Service Schedule for VN-Series 79

The table on the next page is a check-chartto keep track of performed services, it canbe used for planning service work also. Thetable is laid out with the maximum inter-vals in distance. There are also maximumintervals based on the calendar. Each main-tenance interval should be carried out at theindicated accumulated mileage or maxi-mum every fourth month — whichevercomes first.

Before putting your vehicle to work, deter-mine what service schedule works best foryour application. The recommendedschedules in this manual are for typical ap-plications. If the schedule does not fit yourapplication, make modifications based onyour experience of your application. YourVolvo Trucks dealer is also equipped to

help you optimize the maintenance to suityour vehicle and application the best.

When the interval mileage or calendar timeare reached, refer to the check-sheet to seewhat service categories need to be per-formed. Carry out each step described inthe list for each category corresponding tothat interval.

There are references in the lists to pages inthis manual where more information on themaintenance point is available. However,this manual is not to be considered as asubstitute for the Preventive MaintenanceService Manual. Information on orderingTechnical Service Information can be foundon page 170.


Check-Chart for Vehicles with D7 Engine

miles(km)X 1,000

Service Interval miles(km)X 1,000


Service Interval

12.5(20) A 212.5

(340) A 412.5(660) A B C

25(40) A 225

(360) A B C 425(680) A

37.5(60) A B C 237.5

(380) A 437.5(700) A

50(80) A 250

(400) A 450(720) A B C

62.5(100) A 262.5

(420) A B C 462.5(740) A

75(120) A B C 275

(440) A 475(760) A

87.5(140) A 287.5

(460) A 487.5(780) A B C

100(160) A 300

(480) A B C 500(800) A

112.5(180) A B C 312.5

(500) A 512.5(820) A

125(200) A 325

(520) A 525(840) A B C

137.5(220) A 337.5

(540) A B C 537.5(860) A

150(240) A B C 350

(560) A 550(880) A

162.5(260) A 362.5

(580) A 562.7(900) A B C

175(280) A 375

(600) A B C 575(920) A

187.5(300) A B C 387.5

(620) A 587.5(940) A

200(320) A 400

(640) A 600(960) A B C


Check-Chart for Vehicles with D12, Cummins or Detroit Diesel Engines

miles(km)X 1,000



Service Interval

15(24) A ❑

255(408) A ❑

495(792) A B C ❑

30(48) A 270

(432) A B C 510(816) A

45(72) A B C 285

(456) A 525(830) A

60(96) A 300

(480) A 540(864) A B C

75(120) A 315

(504) A B C 555(888) A

90(144) A B C 330

(528) A 570(912) A

105(168) A 345

(552) A 585(936) A B C

120(192) A 360

(576) A B C 600(960) A

135(216) A B C 375

(600) A 615(984) A

150(240) A 390

(624) A 630(1 008) A B C

165(264) A 405

(648) A B C 645(1 032) A

180(288) A B C 420

(672) A 660(1 056) A

195(312) A 435

(696) A 675(1 080) A B C

210(336) A 450

(720) A B C 690(1 104) A

225(360) A B C 465

(744) A 705(1 128) A

240(384) A 480

(768) A 720(1 152) A B C


Maintenance CategoriesCategory A:Every 12,500 miles (20,000 km) or 4 Months(For Vehicles with D7 Engine)Every 15,000 miles (24,000 km) or 4 Months(For Vehicles with D12, Cummins or Detroit Diesel Engine)(Whichever comes first)

1 Perform the daily checks as describedin the beginning of the vehicle Opera-tor’s Manual.

2 Change engine oil. (See page 112.)

3 Change oil filters, both full-flow andbypass. (See page 113.)

4 Lubricate the chassis according to thelubrication chart on page 157.

5 Look for signs of fluid leaks as the ve-hicle is approached.

6 Clean the vehicle if necessary. All ar-eas that need close inspection must beclean.

7 Make sure all appropriate licences andstickers are in place and that they arevalid.

8 Check all telltale and warning indica-tors in instrument cluster. (SeeOperator’s Manual.)

9 Check lights before going on road test.

Road Test

10 Start engine; check starter motor.

11 Operate the clutch several times.Check for smooth engagement and op-eration of clutch brake.

12 Check parking brake hold.

13 While driving, apply brakes and checkfor even stopping and quick release.Check ABS function.

14 Check engine controls and perfor-mance.

15 Check exhaust brake and/or enginebrake operation. Brake shouldengage/disengage as the pedal is ap-plied/released.

16 Shifting through the gears, check trans-mission for smoothness of operation.

17 Check cruise control, if equipped.

18 Check for excessive free play in thesteering wheel. Turning operationshould be smooth and free of roughspots. Check for vibration in the steer-ing wheel or column.

19 Listen for unusual noises. Make surevehicle is riding smoothly; free fromroughness or excessive vibration.

20 Check instrument and gauge operation.

21 Check heater and air conditioning.


In the Shop Yard

22 Check function of pneumatic controls.

23 Check steering column adjustmentfunction, if equipped.

24 Check horns.

25 Record engine low idle.

26 Check low air warning switches. (Seepage 143.)

27 Check manifold dash valve function.

28 Check compressor loading function.

29 Check air brake system for leaks.

30 Check wipers and washer function.

31 Check door switches and controls forfunction.

32 Check the radio function.

33 Check all interior lights.

34 Check interior; upholstery and glass.

35 Check safety belts. (See Operator’sManual.)

36 Check driver and passenger seats.

37 Check sleeper restraint (only sleepermodels).

38 Check sleeper area controls for func-tion (only sleeper models).

39 Open hood, check lock function.

Exterior

40 Inspect steps and grabhandles. Makesure they are properly fastened andthat there are no signs of breakage.

41 Check pedal carrier play.

42 Check door alignment, weather strip-ping and mirrors.

43 Check luggage compartment and doors(only sleeper models).

44 Check all safety equipment.

45 Check fairing access doors, ifequipped.

46 Check all lamps, lights, wires andtrailer light cord for function.

47 Check trailer air hoses, exhaust stack,deck plates and air fairings.

48 Check frame and all brackets for loosebolts and signs of cracks.

49 Check hood condition and its restraintsand splash shields.

50 Check wiper arms and blades.

51 Check clutch slave cylinder for leaks,wear and adjustment.

52 Check around transmission for signsof leaks and wear.

53 Check under cab; exhaust flex linefluid and electric lines for wear orleaks. Check cab suspension.

54 Check rear axle for loose bolts andleaks. Check brackets for shock ab-sorbers, brake chambers and springsfor loose bolts or cracks. Check springU-bolt nut tightening torque. (Seepage 150.)


55 Check rear suspension torque rods,hangers and brackets for looseness orcracks. Check springs for brokenleaves or wear and cracks on airsprings.

56 Inspect rear shock absorbers for leaks.

57 Check rear tandem axle components asthe front tandem axle. Check interaxledriveshaft.

58 Check fifth wheel for loose bolts.Check lock mechanism wear with agauge. Check slide mechanism forfunction and wear (if equipped).

Fuel System

59 Check fuel tank(s) for rotation, leaksand damage. Check J-brackets.

60 Check fuel lines for routing, wear andleaks.

Wheels and Hubs

61 Check wheel rims for signs of cracks.Check tighten wheel nuts. (See page147.)

62 Check tire pressure. Check tire treadfor unusual wear pattern. Measuretread depth. (See page 148.)

63 Check wheel hubs for leaks andproper oil level. (See page 149.)

64 Check wheel bearing clearance.

Brakes

65 Drain air tanks. If a lot of condensateis drained, check air dryer. (See page140.)

66 Measure thickness of brake linings.(See page 141.)

67 Check slack adjuster throw and opera-tion. (See page 141.)

68 Check dual brake system operation(tank check valves). (See page 142.)

69 Inspect air tubing for routing andwear. (See page 143.)

Steering and Suspension

70 Check steering wheel play. (See page138.)

71 Check front springs and fasteners.Check tighten the spring U-bolt nuts.(See page 150.)

72 Check front shock absorbers for leaks.

73 Check steering gear for leaks.

74 Check pitman arm for signs of loose-ness in fasteners.

75 Check steering shaft, drag link and tie-rod for damage and wear.


Engine Compartment

76 Visually inspect the component and allfluid pipes, hoses, seals, gaskets andconnection points on engine, transmis-sion and rear axle(s) for exterior signsof leakage.

77 Inspect all hoses for cracking, cuts,tightness, routing, chafing and evi-dence of leaks. Inspect steel-braidedlines for wear and rust. Inspect clampsfor tightness and insulation.

78 Check radiator package mounts andshroud molding. Clean front of radia-tor if necessary. (See page 123.)

79 Inspect all drive belts on the enginefor cuts, wear, weathering, proper ten-sion and alignment. Check thefunction of the belt tensioner or mea-sure the belt tension. (See page 116.)

80 Test coolant. Adjust additives as nec-essary, change filter if necessary. Ifequipped with long life coolant, do notadd additives. (See page 49.)

81 Change primary (see page 125) andsecondary (see page 127) fuel filters asrecommended.

82 Check clutch fluid level.

83 Check windshield washer fluid.

84 Check engine air filter gauge. Changefilter if necessary. (See “Engine AirFilter, VN” page 115.)

85 Check around turbo for signs of ex-haust or oil leakage. Check bolts forlooseness.

86 Check front engine mounts for wear orcracks.

87 Check A/C compressor mounts for se-cureness and cracks.

88 Check A/C receiver/dryer for signs ofmoisture in the system. Check the A/Cdiagnostic module codes.

89 Check air compressor mounts for se-cureness and cracks.


Category B: Annually1 Check headlight aim and adjust if nec-

essary.

2 Remove wheels and brake drums onall wheels. Inspect all wheel brakecomponents and parts for signs ofwear, warping and cracks.

3 Check function of tractor protectionvalve.

4 Check for spring pin wear. (See page151.)

5 Measure wear in steering knuckles.

6 Measure wear in steering linkage.

7 Check wheel toe-in

8 Check tandem axle alignment.

9 Pressure test cooling system and checkfor leaks and proper relief valve pres-sure.

10 Remove fan belts and check all hubsand pulleys for signs of wear andcracks. Inspect fan for cracks anddamage. Inspect water pump for wearand leaks.

11 Change power steering filter. (Seepage 138.)

12 Remove the cab fresh air filter after60,000 miles (96,000 km) or at least

once per year and clean in a soap so-lution. Dry and reinstall. Change filterafter third use or maximum 240,000miles (385,000 km).

13 Remove inlet air hose to the turbo.Check turbo shaft for wear. Checkhose and inside turbo for signs of oilleakage past the shaft seals.

14 Check starter motor current draw. In-spect mounting for looseness andcracks. Check wires for wear and fray-ing and terminal tightness.

15 Test alternator voltage and ampereoutput. Check mounts for securenessand cracks.

16 Check battery hold-downs for properplacement and tightness. Check allwire terminal condition and tightness.Clean all terminals and apply corro-sion preventive.

17 Check power and ground studs frombatteries and also in engine compart-ment.

18 If equipped with a Volvo engine,check function of engine preheater


Category C: Additional Service Points1 Do the maintenance points as de-

scribed under Categories A and B.

2 Standard antifreeze should be changedevery 4,000 hours. (See page 118 orpage 120.)

3 Extended life antifreeze should havean extender package added at 3,000hours and then changed at 6,000hours. (See page 118 or page 120.)

4 Check coolant thermostat function ev-ery 2,000 hours.

5 Pressure test injectors or adjust height:

• Volvo D7: Every 12 months or2,000 hours.

• Volvo D12: No recommendation.

• Cummins: Every 21 months or3,800 hours.

• Detroit Diesel: Every 21 monthsor 3,800 hours

6 Check and adjust valves on the engine:

• Volvo: Every 12 months or 2,000hours.

• Cummins: Every 21 months or3,800 hours.

• Detroit Diesel: Every 21 monthsor 3,800 hours.

7 Lubricate under the clutch slave cylin-der boot (Rassey cylinder).

NOTE! When checking servo, you shouldalso check servo line and boot, and slavecylinder boot for leaks.

88 Long-Haul Service Schedule for VN-Series

General and Check-Charts

Long-Haul Service is defined here for vehicles that typically travel an annualdistance of 50,000 to 150,000 miles (80,000 to 240,000 km) and operate un-der normal conditions. Typical applications include: regional delivery withmostly freeway driving, interstate or international transportation in 4x2 and6x4 tractor-trailer combinations and straight trucks.

The service categories show maximum allowable intervals. It is very importantto tailor the service to the actual application. Adjust the recommended serviceintervals to your operation.

Line Haul Transport

Typical operations include moving differenttypes of freight in high mileage operations(over 50,000 miles [80,000 km]) per yearoperating on road surfaces of good to ex-cellent concrete or asphalt. Greater than 30miles (50 km) between starting and stop-ping.

Vehicle types are: Auto hauler, doubles,triples, grain hauler, moving van, bulkhauler, refrigerated freight, livestock hauler,pipe hauler, flatbed trailer, tanker, dry van.

Long-Haul Service Schedule for VN-Series 89

The table on the next page is a check-chartto keep track of performed services and canbe used for planning service work also. Thetable is laid out with the maximum inter-vals in distance. There are also maximumintervals based on the calendar. Each main-tenance interval should be carried out at theindicated accumulated mileage or maxi-mum every fourth month — whichevercomes first.

Before putting your vehicle to work, deter-mine what service schedule works best foryour application. The recommended sched-ules in the is manual are for typicalapplications. If the schedule does not fityour application, make modifications basedon your experience of your application.Your Volvo Trucks dealer is also equippedto help you optimize the maintenance tosuit your vehicle and application the best.

When the interval mileage or calendar timeis reached, refer to the check-sheet to seewhat service categories need to be done.Carry out each step described in the list foreach category corresponding to that interval.

There are references in the lists to pages inthis manual where more information on the

maintenance point is available. However,this manual should not be considered asubstitute for the Preventive MaintenanceService Manual. Information on orderingTechnical Service Information can be foundon page 170.

90 Long-Haul Service Schedule for VN-Series

Check-Chart for D12, Cummins or Detroit Diesel Engines on Normal Oil

miles(km)X 1,000



Service Interval

15(24) A 255

(408) A 495(792) A B C

30(48) A 270

(432) A B C 510(816) A

45(72) A B C 285

(456) A 525(830) A

60(96) A 300

(480) A 540(864) A B C

75(120) A 315

(504) A B C 555(888) A

90(144) A B C 330

(528) A 570(912) A

105(168) A 345

(552) A 585(936) A B C

120(192) A 360

(576) A B C 600(960) A

135(216) A B C 375

(600) A 615(984) A

150(240) A 390

(624) A 630(1 008) A B C

165(264) A 405

(648) A B C 645(1 032) A

180(288) A B C 420

(672) A 660(1 056) A

195(312) A 435

(696) A 675(1 080) A B C Pub

_ce

Maintenance 91

Engine Maintenance

Exhaust Emissions

General

USAThe Federal Clean Air Act, Section 203 (a)(3), states the following concerning the re-moval of air pollution control devices ormodification of a certified engine to a non-certified configuration:

“The following acts and the causing thereofare prohibited:

(3) For any person to remove or render in-operative any device or element of designinstalled on or in a motor vehicle or motorvehicle engine in compliance with regula-tions under this part prior to its sale anddelivery to the ultimate purchaser, or forany manufacturer or dealer knowingly toremove or render inoperative any such de-sign after sale and delivery to the ultimatepurchaser.”

Specifically, please note that no person maymake such changes prior to the sale and

delivery of the vehicle to the ultimate pur-chaser, and, in addition, no manufacturer ordealer may make take such action after saleand delivery of the vehicle to the ultimatepurchaser. The law provides a penalty of upto $10,000 for each violation.

Modifications, such as reprogramming ofthe fuel system so the engine will exceedthe certified horsepower or torque, or re-moving the mufflers are examples of illegalchanges.

Changes should not be made to a certifiedengine that would result in an engine thatdoes not match the configuration of an en-gine model that is currently certified tomeet Federal Standards.

CanadaThe same conditions that apply in the USAapply to Canada, with one exception. Afterthe vehicle is sold to a retail customer, thatis, the end user, the jurisdiction controllingthe emission control devices becomes theprovince in which the vehicle is licensed.No changes should be made that render anyor all of the devices inoperative.

Should the owner/operator wish to makeany changes to the emission control de-vices, check with the provincial authoritybefore making any such changes.

MexicoThe same conditions that apply in the USAapply to Mexico. Refer to the MexicanFederal Law for Emission Control whichadheres to EPA regulations. No changesshould be made that render any or all ofthe emissions control devices inoperative.

Should the owner/operator wish to makeany changes to the emission control de-vices, check with the state authority beforemaking any such changes.

92 Maintenance

California Emission Control Warranty Statement

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Volvo Trucks North America , Inc. (VTNA) arepleased 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 stringentanti-smog standards. Volvo Trucks North America, Inc. must warrant the emission controlsystem on your vehicle for the periods of time listed listed below provided there has beenno abuse, neglect or improper maintenance of your vehicle.

Your emission control system may include parts such as carburetor or fuel injection systemand engine computer. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Volvo Trucks North America, Inc. will repair yourvehicle at no cost to you including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE

This warranty is applicable for a period of five years, 100,000 miles or 3,000 hours of op-eration, whichever first occurs. If an emission-related part of your vehicle is defective, thepart will be repaired or replaced by Volvo Trucks North America, Inc.

This is your emission control system DEFECTS WARRANTY.

OWNER’S WARRANTY RESPONSIBILITIES

As the vehicle owner, you are responsible for the performance of the required maintenancelisted in your owner’s manual. Volvo Trucks North America, Inc. recommends that you re-tain all receipts covering maintenance on your truck but Volvo Trucks North America, Inc.cannot deny warranty solely for the lack of receipts or for your failure to ensure the per-formance of all scheduled maintenance.

You are responsible for presenting your vehicle to a Volvo Trucks North America, Inc.dealer as soon as a problem exists. The warranty repairs should be completed in a reason-able amount of time, not to exceed 30 days.

As the vehicle owner, you should also be aware that Volvo Trucks North America, Inc.may deny you warranty coverage if your vehicle or a part has failed due to abuse, neglect,improper maintenance or unapproved modifications.

If you have any questions regarding your warranty rights and responsibilities, you shouldcontact Volvo Trucks North America, Inc., Warranty Administration, (336) 393-2000 orthe California Air Resources Board at 9480 Telstar Avenue, El Monte, CA 91731.

Maintenance 93

EMISSION CONTROL SYSTEM WARRANTY

Volvo Trucks North America, Inc. WARRANTS TO THE ORIGINAL OWNER, ANDEACH SUBSEQUENT OWNER, OF A NEW TRUCK POWERED BY A VOLVODIESEL 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 regulationsof the U.S. Environmental Protection Agency and the California California Air Re-sources Board applicable at the time of the manufacture; and

2 Is free from defects in material and workmanship which will cause the emission con-trol components not to function as designed for a period of use of 5 years or 100,000miles or 3,000 hours of engine operation, whichever comes first.

The 5 years/100,000 miles/3,000 hour warranty period shall begin on the date the vehicleis first delivered to the first retail purchaser or if the vehicle is placed in service as ademonstrator company vehicle prior to the sale at retail, on the date the vehicle is the firstplaced in service.

The emission control system of your new Volvo engine was designed, built and tested us-ing genuine Volvo parts, and the engine is certified as being in conformity with Federaland California emission control regulations. Accordingly, it is recommended that any re-placement parts used for maintenance, replacement or repair without invalidating thiswarranty; the cost of such services or or parts, however, will not be covered under the war-ranty except in an emergency situation. A part not being available or a repair not beingcompleted within 30 days also constitutes an emergency.

Use of replacement parts which are not of equivalent quality may impair the effectivenessof emission control systems. If other than Volvo parts are used for maintenance, ownershould obtain assurances that suck parts are warranted by their manufacturer to be equiva-lent to genuine Volvo parts. However, the use of other than Volvo replacement parts doesnot invalidate the warranty on other components, unless such parts cause damage to war-ranted parts.

Repairs and service covered by the warranty will be performed by an authorized VolvoTrucks North America, Inc. dealer at his place of business with no charge for parts or la-bor (including diagnosis) using Volvo parts for the emission control system, that requiresreplacement and is covered by the warranty and found defective. In case of an emergency,where an authorized Volvo Trucks North America, Inc. dealer is not available, repairs maybe performed at any available service establishment or by the owner, using any equivalentreplacement parts and Volvo Trucks North America, Inc. will reimburse the owner for suchrepairs (including diagnosis) not to exceed Volvo Trucks North America, Inc’s suggestedretail retail price for the warranted parts and the labor rate appropriate for the geographicalarea and the tasks performed.

Replaced parts and paid invoices must be presented to a Volvo Trucks North America, Inc.dealer for reimbursement.

94 Maintenance

The emissions control parts covered by this Emission Control System Warranty are listedunder "What Is Covered by the Emissions Warranty." You are responsible for the perfor-mance of all required maintenance on your new Volvo engine, including maintenance orrepairs needed due to severe operating conditions. Volvo Trucks North America, Inc. willnot deny a warranty claim solely because you have no record of maintenance. However,Volvo Trucks North America, Inc. may deny a warranty claim if your failure to performrequired maintenance resulted in the failure of a warranted part. Receipts covering theperformance of regular maintenance should be retained in the event questions arise con-cerning maintenance. The receipts should be transferred to each subsequent owner of thevehicle with the emission warranted engine.

CUSTOMER ASSISTANCE

Volvo Trucks North America, Inc. wishes to help to assure that the Emission Control Sys-tem Warranty is properly administered. In the event that you do not receive the warrantyservice to which you believe you are entitled under the Emission Control System Warranty,you should contact Volvo Trucks North America, Inc. Warranty Administration, (336) 393-2000. The address and telephone number of each Regional Office is in your vehicleowner’s manual. If you need additional assistance or information concerning the EmissionControl System Warranty, contact: Volvo Trucks North America, Inc., Warranty Adminis-tration, (336) 393-2000.

WHAT IS NOT COVERED BY THE EMISSION WARRANTY

This warranty does not cover:

1 Malfunctions in any part caused by any of the following: misuse, abuse, improperadjustments unless performed by a Volvo Trucks North America, Inc. dealer, modifi-cations, alterations, tampering, disconnection, improper or inadequate maintenance, oruse of fuels not recommended for the engine as described in the owner’s manual.

2 Damage resulting from accident, acts of nature or other events beyond the control ofVolvo Trucks North America, Inc.

3 The replacement of expendable maintenance items such as filters, hoses, belts, oil,thermostat and coolant made in connection with scheduled maintenance services oncethese parts have been replaced. Any parts replaced under warranty before the first re-quired replacement point are warranted for the remainder of the warranty period.

4 Replacement items which are not genuine Volvo parts or not authorized by VolvoTrucks North America, Inc.

5 Loss of time, inconvenience, loss of use of vehicle or engine, or commercial loss.6 Any vehicle on which the odometer or hourmeter has been disconnected or the

mileage (or hours) has been altered so the actual usage cannot be readily be deter-mined.

7 Any vehicle registered and normally operated outside the United States.

Maintenance 95

WHAT IS COVERED BY THE EMISSION WARRANTY

The following is a list of the items that are considered a part of the Emission Control Sys-tems and are covered by the Emission Warranty when installed as original equipment byVolvo Trucks North America, Inc. on vehicles which were built to conform to Environ-mental Protection Agency and California Air Resources Board regulations

IMPORTANT - This may not include expendable maintenance items. Emission relatedparts requiring scheduled maintenance are warranted until their first scheduled replacementpoint.

I. Fuel Injection System

II. Air Induction System

A. Intake Manifold

B. Turbocharge System

C. Charge Air Cooler (Intercooler)

III. Exhaust Manifold

IV. Miscellaneous Items Used in Above Systems

A. Hose, clamps, fittings and tubing

B. Pulleys, belts and idlers

C. Vacuum, temperature, and time sensitive valves and switches

D. Mounting hardware, sealing gaskets and PVC (if applicable)

THIS CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT IN NO WAYREPLACES, MODIFIES, ALTERS OR SUPERSEDES THE TRUCK WARRANTY CER-

TIFICATE, ITS TERMS AND CONDITIONS, AND ITSLIMITATIONS AND EXCLUSIONS.

BE CERTAIN YOU READ AND UNDERSTAND ALL WARRANTIES WHICHACCOMPANIED YOUR VEHICLE.

NOTE! Warranty coverage is subject tochange without notice. Contact your VolvoTruck dealer for the current warrantystatement.

96 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. Incompliance with section 207(b) of the Clean Air Act, VTNA must warrant the emissioncontrol system on your vehicle for the periods of time listed listed below, provided therehas been no abuse, neglect or improper maintenance of your vehicle.For instructions on proper maintenance, including time and/or mileage intervals at whichsuch maintenance is to be performed, see your "Operator’s Manual-Volvo VN Maintenanceand Engine."

Your emission control system may include parts such as carburetor or fuel injection systemand engine computer. Also included may be hoses, belts, connectors or other emission-related assemblies.Refer to the Warranty Certificate for complete coverage details.Federal warranty provisions apply to all vehicles sold in all U.S. states and territoriesregardless of whether a state has enacted state warranty provisions that differ from the fed-eral provisions.Where a warrantable condition exists, VTNA will repair your vehicle at no cost to you (in-cluding diagnosis, parts and labor) any emission control device or system which causes avehicle to fail an EPA-approved emission short test during its useful life, if you have main-tained and operated the vehicle in accordance with the written instructions of VTNA.

If a facility at which the vehicle is initially presented for repair is unable for any reason tohonor the claim, then, unless you waive in writing, the repair facility must forward theclaim to VTNA warranty Administration, (336) 393-2000.

MANUFACTURER’S WARRANTY COVERAGE

This warranty is applicable for a period of five years, 100,000 miles or 3,000 hours of op-eration, whichever first occurs. If an emission-related part of your vehicle is defective, thepart will be repaired or replaced by VTNA.

This is your emission control system DEFECTS WARRANTY.

Maintenance 97

OWNER’S WARRANTY RESPONSIBILITIES

As the vehicle owner, you are responsible for the performance of the required maintenancelisted in your owner’s manual. Volvo Truck North America, Inc (VTNA) recommends thatyou retain all receipts covering maintenance on your truck, but VTNA cannot deny war-ranty solely for the lack of receipts or for your failure to ensure the performance of allscheduled maintenance.

You are responsible for presenting your vehicle to a VTNA dealer as soon as a problemexists. The warranty repairs should be completed in a reasonable amount of time, not toexceed 30 days. Claim procedures are outlined in the "Volvo Service Operations Manual."

As the vehicle owner, you should also be aware that VTNA may deny you warranty cover-age if your vehicle or a part has failed due to abuse, neglect, improper maintenance orunapproved modifications.

If you have any questions regarding your warranty rights and responsibilities, you shouldcontact VTNA Warranty Administration, (336) 393-2000.

98 Maintenance

EMISSION CONTROL SYSTEM WARRANTY

Volvo Trucks North America, Inc. WARRANTS TO THE ORIGINAL OWNER, ANDEACH SUBSEQUENT OWNER, OF A NEW TRUCK POWERED BY A VOLVODIESEL 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 theU.S. Environmental Protection Agency, applicable at the time of the manufacture; and

2 Is free from defects in material and workmanship which will cause the emission con-trol components not to function as designed for a period of use of 5 years or 100,000miles or 3,000 hours of engine operation, whichever comes first.

The 5 years/100,000 miles/3,000 hour warranty period shall begin on the date the vehicleis first delivered to the first retail purchaser or if the vehicle is placed in service as ademonstrator company vehicle prior to the sale at retail, on the date the vehicle is the firstplaced in service.

The emission control system of your new Volvo engine was designed, built and tested us-ing genuine Volvo parts, and the engine is certified as being in conformity with federalemission control regulations. Accordingly, it is recommended that any replacement partsused for maintenance, replacement or repair be Volvo parts.

The owner may elect to have maintenance, replacement or repair of the emission controlcomponents and systems performed by any vehicle repair establishment or individual andmay elect to use parts other than Volvo parts for such maintenance, replacement or repairwithout invalidating this warranty; the cost of such services or parts, however, will not becovered under the warranty except in an emergency situation. A part not being available ora repair not being completed within 30 days also constitutes an emergency.

Use of replacement parts which are not of equivalent quality may impair the effectivenessof emission control systems. If other than Volvo parts are used for maintenance, ownershould obtain assurances that such parts are warranted by their manufacturer to be equiva-lent to genuine Volvo parts. However, the use of other than Volvo replacement parts doesnot invalidate the warranty on other components, unless such parts cause damage to war-ranted parts.

Repair and service covered by the warranty will be performed by an authorized VTNAdealer at his place of business with no charge for parts or labor (including diagnosis). Thedealer uses Volvo parts for the emission control system, that required replacement and iscovered by the warranty and if found defective.

In case of an emergency, where an authorized VTNA dealer is not available, repairs maybe performed at any available service establishment or by the owner, using any equivalentreplacement parts and VTNA will reimburse the owner for such repairs (including diagno-sis) not to exceed VTNA’s suggested retail retail price for the warranted parts and thelabor rate appropriate for the geographical area and the tasks performed.

Replaced parts and paid invoices must be presented to a VTNA dealer for reimbursement.

Maintenance 99

The emissions control parts covered by this Emission Control System Warranty are listedunder "What Is Covered by the Emissions Warranty." You are responsible for the perfor-mance of all required maintenance on your new Volvo engine, including maintenance orrepairs needed due to severe operating conditions. VTNA will not deny a warranty claimsolely because you have no record of maintenance. However, VTNA may deny a warrantyclaim if your failure to perform required maintenance resulted in the failure of a warrantedpart. Receipts covering the performance of regular maintenance should be retained in theevent questions arise concerning maintenance. The receipts should be transferred to eachsubsequent owner of the vehicle with the emission warranted engine.

If the warranty claim is denied, VTNA shall provide a written basis for denial within 30days or a shorter time if required by local, state or federal law. Failure to provide writtenbasis for denial within 30 days or shorter time limit required by state, local or federal lawor for reasons not attributable to the vehicle owner or events beyond the control of VTNAshall result in VTNA being responsible for repairing the vehicle free of charge to the vehi-cle owner.

CUSTOMER ASSISTANCE

Volvo Trucks North America, Inc. wishes to help assure that the Emission Control SystemWarranty is properly administered. In the event that you do not receive the warranty ser-vice to which you believe you are entitled under the Emission Control System Warranty,you should contact Volvo Trucks North America, Inc. Warranty Administration, (336) 393-2000. The address and telephone number of each Regional Office is in your vehicleowner’s manual. If you need additional assistance or information concerning the EmissionControl System Warranty, contact: Volvo Trucks North America, Inc., Warranty Adminis-tration, (336) 393-2000.

You can obtain further warranty information or report violations of the terms of EmissionsPerformance Warranty by contacting the Manager, Certification and Compliance Division(6405J), Warranty Claims, Enviromental Protection Agency, Ariel Rios Building, 1200Pennsylvania Ave. N.W., Washington, D.C. 20460.

100 Maintenance

WHAT IS NOT COVERED BY THE EMISSION WARRANTY

This warranty does not cover:

1 Malfunctions in any part caused by any of the following: misuse, abuse, improper ad-justments unless performed by a VTNA dealer, modifications, alterations, tampering,disconnection, improper or inadequate maintenance, or use of fuels not recommendedfor the engine as described in the owner’s manual.

2 Damage resulting from accident, acts of nature or other events beyond the control ofVTNA.

3 The replacement of expendable maintenance items such as filters, hoses, belts, oil,thermostat and coolant made in connection with scheduled maintenance services oncethese parts have been replaced. Any parts replaced under warranty before the first re-quired replacement point are warranted for the remainder of the warranty period.

4 Replacement items which are not genuine Volvo parts or not authorized by VTNA.5 Loss of time, inconvenience, loss of use of vehicle or engine, or commercial loss.6 Any vehicle on which the odometer or hourmeter has been disconnected or the

mileage (or hours) has been altered so the actual usage cannot be readily determined.7 Any vehicle registered and normally operated outside the United States.

Maintenance 101

WHAT IS COVERED BY THE EMISSION WARRANTY

The following is a list of the items that are considered a part of the Emission Control Sys-tems and are covered by the Emission Warranty when installed as original equipment byVTNA on vehicles which were built to conform to Environmental Protection Agency regu-lations.

IMPORTANT - This may not include expendable maintenance items. Emission relatedparts requiring scheduled maintenance are warranted until their first scheduled replacementpoint.

I. Fuel Injection System

II. Air Induction System

A. Intake Manifold

B. Turbocharge System

C. Charge Air Cooler (Intercooler)

III. Exhaust Manifold

IV. Miscellaneous Items Used in Above Systems

A. Hose, clamps, fittings and tubing

B. Pulleys, belts and idlers

C. Vacuum, temperature, and time sensitive valves and switches

D. Mounting hardware, sealing gaskets and PVC (if applicable)

THIS EMISSIONS PERFORMANCE WARRANTY STATEMENT IN NO WAYREPLACES, MODIFIES, ALTERS OR SUPERSEDES THE TRUCK WARRANTY CER-

TIFICATE, ITS TERMS AND CONDITIONS, AND ITSLIMITATIONS AND EXCLUSIONS.

BE CERTAIN YOU READ AND UNDERSTAND ALL WARRANTIES WHICHACCOMPANIED YOUR VEHICLE.

102 Maintenance

Noise EmissionsVolvo Trucks North America, Inc. warrantsto the first person who purchases this vehi-cle for purposes other than resale and toeach subsequent purchaser, that this vehicleas manufactured by Volvo Trucks NorthAmerica, Inc. was designed, built andequipped to conform, at the time it leftVolvo Trucks North America, Inc’s control,with all applicable U.S. EPA Noise ControlRegulations.

This warranty covers this vehicle as de-signed, built and equipped by Volvo TrucksNorth America, Inc., and is not limited toany particular part, component or system ofthe vehicle manufactured by Volvo TrucksNorth America, Inc. Defects in design, as-sembly or in any part, component or systemof the vehicle as manufactured by VolvoTrucks North America, Inc., which, at thetime it left Volvo Trucks North America,Inc’s control, caused noise emissions to ex-ceed Federal standards, are covered by thiswarranty for the life of the vehicle.

Maintenance 103

Tampering with Noise Control SystemFederal law prohibits the following acts orthe causing thereof:

(1) The removal or rendering inoperative byany person, other than for purposes ofmaintenance, repair, or replacement, of anydevice or element of design incorporatedinto any new vehicle for the purpose ofnoise control prior to its sale or delivery tothe ultimate purchaser or while it is in use;

or

(2) the use of the vehicle after such deviceor element of design has been removed orrendered inoperative by any person.

Among those acts presumed to constitutetampering are the acts listed:

Noise Shields and InsulationRemoving or rendering inoperative the en-gine and/or transmission noise deadeningpanels, shields or insulating materials.

Removing or rendering inoperative the cab-tunnel or hood noise insulating materials.

Removing or rendering inoperative anytruck body mounted sound insulation com-ponents and/or shields (cab or fendershields, skirts, wheel housing splashshields, etc.).

Engine Control and Fuel SystemsRemoving or rendering inoperative, ormodifying the engine control system (suchas the ECU or the fuel system components)in order to allow the engine to operate out-side of the manufacturer’s specifications(e.g., exceeding the manufacturer’s enginespeed limits).

104 Maintenance

Cooling SystemRemoving or rendering inoperative coolingsystem components (such as the tempera-ture modulated fan clutch, fan shroud, fanring, recirculation shields, etc.).

Exhaust SystemRemoving or rendering inoperative exhaustsystem components (such as the muffler,pipes, clamps, etc.).

Air Intake SystemRemoving or rendering inoperative air in-take/induction system components (filter,filter housings, ducts, etc.).

Maintenance 105

Noise Control System, Operator Inspectionand Maintenance Requirements

Before inspecting a vehicle, set the park-ing brakes, place the transmission inneutral, and block the wheels. Failure todo so can result in unexpected vehiclemovement and can cause serious per-sonal injury or death.

A Noise Control System Maintenance Logis located in “Noise Control Log” page110. This log should be used to documentall Noise Control System related mainte-nance, whether the maintenance resultsfrom a specific noise control system inspec-tion, or a deficiency identified duringanother general maintenance event.

If additional log space is needed, furtherentries may be added on a separate sheet ofpaper. Store these additions with the mainlog to preserve a comprehensive record. Itis recommended that copies of all noiseemissions related maintenance invoices beretained.

The following Noise Control System in-spection and maintenance instructionscontain suggested maintenance intervals.These intervals may need adjustment inorder to best accommodate the specific ve-hicle usage. The following instructions onlyconcern Noise Emissions related items anddo not address or modify any general vehi-cle maintenance requirements.

106 Maintenance

Exhaust System

Make sure the exhaust system is intact. In-spect for damage, misalignment and/orleakage. Primary system components re-quiring noise related inspection includemuffler body, exhaust manifold, tur-bocharger, and all exhaust system (rigidand flexible) piping. Closely check the sys-tem for exhaust leaks. Special attentionshould be given to all welds, seams, gas-kets, support points, clamps, couplings andconnections.

Inspect all exhaust system fasteners, brack-ets, and clamps for damage and tightness.Check integrity of internal muffler bafflingby revving the engine through normal oper-ating speeds. Excessive rattling sounds orvery loud operation indicates a failurewithin the muffler.

Repair or replace components as required.See Service Information in Group 177-500,Preventive Maintenance, Basic Service VN,VHD and Group 177-501 Preventive Main-tenance, Annual Service VN, VHD fordetailed repair and replacement procedures.

Inspection interval: Once every year.

WARNING

Hot engine! Keep yourself clear of allmoving parts or hot engine parts, ex-haust gases, and/or fluids. A hot engine,exhaust, and/or fluids can cause burns.

Maintenance 107

Air Intake/ Air Induction System

Make sure the air intake system is intact.Inspect components for damage, misalign-ment and/or leakage. Primary systemcomponents requiring noise related inspec-tion include the air cleaner housing, aircleaner element, turbocharger, charge aircooler and intake manifold.

Also inspect all ducts, pipes, hoses, tubingand elbows used to interconnect the system.Special attention should be given to allwelds, seams, gaskets, support points,clamps, couplings and connections.

Inspect all intake system fasteners, brack-ets, and clamps for damage and tightness.



108 Maintenance

Cooling System

WARNING

Do not work near the fan with the en-gine running or the ignition in the ONposition. The engine fan can engage atany time without warning. Anyone nearthe fan when it turns on could be seri-ously injured.

Visually inspect cooling system compo-nents for damage, and/or misalignment.

Primary system components requiring noiserelated inspection include fan blades, fanclutch, fan shroud, fan ring, and recircula-tion shields. Check fan blades, fan ring, fanshroud, and recirculation shields for anydamage. Verify that fan blades clear the fanring. Inspect all related fasteners, brackets,and clamps for damage and tightness. Con-firm operation of temperature modulatedfan clutch.



Maintenance 109

Sound Shielding and Insulation Devices

Make sure sound shielding and insulatingdevices are intact. Inspect components fordamage. Primary system components re-quiring noise related inspection include thehood, engine compartment insulating mate-rials (including hood insulation, bulkheadinsulation, doghouse insulation, etc.) splashshields, cab skirts, fender shields, and bodypanels. Inspect all related fasteners, brack-ets, and clamps for damage and tightness.



110 Maintenance

Noise Control Log

NOISE CONTROL SYSTEM MAINTENANCE LOG

DATE MILEAGE MAINTENANCEPERFORMED

MAINTENANCEFACILITY

Maintenance 111

Maintenance Hazards


Do not attempt to repair or service thisvehicle without having sufficient train-ing, correct service literature and theproper tools. Failure to follow this couldlead to personal injury or death.

CAUTION

Prolonged contact with used engine oilmay be harmful. Use rubber gloves whenhandling used oil. Wash skin thoroughlyif it comes in contact with used oil.

NOTE! Read all the safety informationstarting on page 3 before working on thevehicle.

112 Maintenance

Oil Change


WARNING

A hot engine and engine oil can causeserious burns. Take precautions whendraining the oil. Wear gloves and let theengine cool down before draining.

For information on the type of oil recom-mended for your engine, see “Engine Oil”page 63 for application tips and “Viscosityand Capacity Tables” page 161 for quanti-ties and viscosities or refer to other enginemanufacturer’s operator’s manual.

It is important to drain as much oil as pos-sible. Try to change oil immediately afterdriving, when the oil is warm. Always re-place the oil filters when changing oil.

NOTE! Always dispose of oil according toFederal or local regulations. Used oildisposed of in nature or waterways contam-inates our drinking water and kills wildlife.

T1006392

D7 Engine:

A Oil plug

B Oil Filter

CAUTION

Prolonged contact with used engine oilmay be harmful. Use rubber gloves whenhandling used oil. Wash skin thoroughlyif it comes in contact with used oil.

Maintenance 113

Oil Filters


WARNING

A hot engine and engine oil can causeserious burns. Take precautions whendraining the oil. Wear gloves and let theengine cool down before draining.

CAUTION

Use only the engine manufacturer’s oilfilter for replacement. Use of an oil filternot built to specification could result insevere damage to bearings, crankshaft,etc. as a result of unfiltered oil enteringthe lubrication system.

NOTE! Always dispose of oil filters ac-cording to Federal or local regulations.Used oil disposed of in nature or water-ways contaminates our drinking water andkills wildlife.

Install new filters as follows:

• Coat the filter gasket with oil.

• Install the filter and turn it by handuntil the gasket makes contact with thesealing surface.

• Then turn the filter a further 3/4 turn.

W2003173

D12 Oil Filters

W2003078

D7 Oil Filters:

1 Full-flow Filter

2 Bypass Filter

114 Maintenance

Checking Oil LevelNOTE! Do not let the oil level fall belowthe lower marking on the dipstick. Do notoverfill so the level is above the uppermarking on the dipstick.

Wait five minutes after turning off the en-gine before checking the oil level. Thisgives the oil time to drain back to the oilpan.

Crankcase Air Breather

CAUTION

If the crankcase breather is not main-tained on a regular basis, it will becomeplugged. When plugged, excessivecrankcase pressure buildup may causecrankshaft seal leakage.

Check and clean the crankcase ventilationsystem at every annual service.

Maintenance 115

Engine Air Filter, VN


The engine air filter is monitored by a pres-sure restriction gauge mounted on the airfilter housing. The gauge may be connectedto the instrumentation to give a telltale sig-nal when the air filter needs to be changed;see the vehicle Operator’s Manual. A man-ual gauge needs to be inspected regularly.When the gauge shows in the red band, thefilter should be replaced. Replace the filteraccording to the gauge or after a maxi-mum of two years, whichever comes first.

CAUTION

Continued operation with the gaugeshowing in the red may cause damage tothe engine. Operating the engine with adamaged filter allows dust to pass di-rectly into the engine, causing damage.Replace damaged or clogged filters.

To change the filter, remove the fastenersaround the outer cover and remove thecover. Pull out the old filter from the con-tainer and discard.

Make sure the new filter seal is in goodcondition. Install the new filter in the filtercontainer so the seal enters the guide in theback of the container. Reinstall the cover.

W2003507

W2002521

W2002522

116 Maintenance

Fan Drive Belts


WARNING


All engine belts should be checked at eachservice point. Inspect for cracked or frayedmaterial. Most belts have automatic belttensioners to keep the correct tensionwithout adjustment. Some belts are still ad-justed with an adjusting mechanism to getthe correct tension. Check with your dealerto get the correct tension value for the dif-ferent belts.

CAUTION

Do not tighten the belts over recom-mended values. Over-tightening a beltmay damage bearings as well as belts.

W2001070

Maintenance 117

Flushing Cooling System, D7

Coolant Filter

WARNING


When using standard antifreeze, use acoolant filter containing the additivesnecessary for replenishing the used-up ad-ditives. If using extended life antifreeze, thecoolant filter should be empty. Do not in-stall additive type filters on an engine filledwith extended life type coolant.

See page 49 for information on coolanttesting and page 48 for standard coolant orpage 53 for extended coolant changeintervals.

W2002709

118 Maintenance

Draining Cooling System


WARNING

Do not remove the cap to the coolantsurge tank while the engine and radiatorare still hot and under pressure. Scaldingfluid and/or steam may be blown outcausing serious burns.

WARNING


W2003079

1 Remove system fill cap.

2 Open drain cocks located in the bot-tom of the radiator and on the block(You may have to use special tool9996049 for quick-connect fittings).

3 Open the drain valve on the air com-pressor.


W0001746

Special tool 9996049

Maintenance 119

Flushing Cooling SystemBefore filling, flush out the system thor-oughly with clean water. Before flushingout the radiator, remove the lower radiatorhose to allow a quicker and more efficientdraining.

When flushing the radiator, keep the waterpressure low so the radiator tubes are notdamaged.

W2003080

Filling Cooling SystemAlways use a pre-mixed solution of 50/50clean water and antifreeze. Do not fill sys-tem with water and then add antifreeze. Amixture with less than 35% antifreeze doesnot give adequate corrosion protection.Concentrations of antifreeze above 60% donot give added freeze protection. The sys-tem is self-venting.

1 Fill the system with clean coolantthrough the fill neck in the middle ofthe surge tank. The fill rate is not toexceed 2 gpm (8 L/min.). The engineshould not be running and the heatercontrol should be on WARM.

2 Fill up to the top of the surge tank.

3 Check the level after running the en-gine at high idle for approximatelyfive minutes. Add coolant as required.

W2003082

W2003081

120 Maintenance

Flushing Cooling System, D12

Draining Cooling System


WARNING

Do not remove the cap to the coolantsurge tank while the engine and radiatorare still hot and under pressure. Scaldingfluid and/or steam may be blown outcausing serious burns.

WARNING


W2002059

1 Remove system fill cap.

2 Open drain cocks located in the bot-tom of the radiator and on the block(You may have to use special tool9996049 for quick-connect fittings).

3 Open the drain valve on the air com-pressor.


W0001746

Special tool 9996049

Maintenance 121

Flushing Cooling SystemBefore filling, flush out the system thor-oughly with clean water. Before flushingout the radiator, remove the lower radiatorhose to allow a quicker and more efficientdraining.

When flushing the radiator, keep the waterpressure low so the radiator tubes are notdamaged.

W2002057

Filling Cooling SystemAlways use a pre-mixed solution of 50/50clean water and antifreeze. Do not fill sys-tem with water and then add antifreeze. Amixture with less than 35% antifreeze doesnot give adequate corrosion protection.Concentrations of antifreeze above 60%does not give added freeze protection. Thesystem is self-venting.

1 Fill the system with clean coolantthrough the fill neck in the middle ofthe surge tank. The fill rate is not toexceed 2 gpm (8 L/minute). The en-gine should not be running and theheater control should be on WARM.

2 Fill up to the top of the surge tank.

3 Check the level after running the en-gine at high idle for approximatelyfive minutes. Add coolant as required.

W2003082

122 Maintenance

Turbo and Charge Air CoolerGeneral

WARNING

Do not remove, attach or tighten tur-bocharger air intake ducting while theengine is operating, or operate the enginewhile the ducting is removed. Workingaround the turbo with the ducting re-moved may cause severe personal injury.

Visually inspect turbo mountings, intakeand exhaust ducting and connections forleaks on a daily basis. Check oil inlet andoutlet for leaks or signs of restrictions tooil flow. Check for unusual noise or vibra-tion. If any faults are detected, do notoperate the engine until the cause is deter-mined and repaired.

If oil leaks internally from the tur-bocharger to the engine intake, the oilacts as a fuel. Watch for excessive ex-haust smoke. Do not operate engineuntil problem is corrected. Loss of en-gine control may lead to an accidentcausing severe personal injury or death.

Periodically inspect the front of theradiator/charge-air-cooler package forbuildup of dirt, mud, insects, etc. Overtime, there may be a build-up of dirt, mud,insects, etc., between the radiator andcharge-air-cooler. Inspect for build-up andremove the cooler package to clean, ifnecessary.

Maintenance 123

Cleaning Charge-Air-Cooler and Radiator Package

Over time, dirt and insects will accumulatebetween the fins of the radiator, air condi-tioning condenser and charge-air-cooler.The reduced air flow reduces the heat trans-fer from the components to the air. Thisincreases the load on the fan and air condi-tioning compressor and can result in engineoverheating and other performance relatedproblems, such as high fuel consumption,etc. Make sure the radiator/charge-air-cooler package is inspected regularly. Cleanif necessary.


WARNING

Always wear eye protection when clean-ing radiator, charge-air-cooler andcondenser. Failure to follow this recom-mendation may result in eye injury.

The simplest method to clean the packageis to use air pressure or a water stream.This should be done from the back of thecore. Air pressure should not exceed 30 psi(200 kPa) for radiator and charge-air-coolercores. The use of a fin comb is also a goodtool to loosen bugs and dirt from the fins.

If dirt can not be cleaned off with this pro-cedure, consult your Volvo Truck dealer.

Inspect the charge-air-cooler for cracks atevery inspection. Do not operate the vehiclewith a damaged or broken charge-air-cooler. To do so would void the warrantyand the engine will not meet emission regu-lation requirements.

W2001496

124 Maintenance

Replacing Fuel Filters, Volvo EnginesGeneralThe filters are an important part of the fuelsystem. Always replace the filters at therecommended intervals and use the recom-mended filter types for the best engineoperation and service life.

A primary fuel filter is located on theouter, right or left frame rail in the enginecompartment. This filter consists of a filtercartridge, a water separation bowl and mayhave a fuel heater built in.

W2001067

The secondary fuel filter is located on theleft side, under the control unit on D12 andon the left, front side on the D7 engine. Thefilter is contained in a disposable cartridge.

W2001079

Fuel Filter Change IntervalsFor information on Primary Fuel Filter seemanufacturer’s recommendation or see Ser-vice Information in Group 175-001, Oil andFilter Change Interval for Volvo Compo-nents, All Models.

For Secondary Fuel Filter, Maximumchange interval is 1,500 miles (24,000km).

Maintenance 125

Fuel System ServiceChanging the Primary Fuel Filter


The standard primary filter is manufacturedby Racor. For Volvo engines, use only their30 micron (red coded) element. Failure todo so could result in reduced power.

To replace the primary fuel filter element:

1

To avoid potential fire hazard, do notservice any part of the fuel system whilesmoking or in the presence of flames,sparks or hot surfaces, or when workingon an operating engine. Failure to followthese precautions can result in fire, per-sonal injury or death. Always wearadequate protective clothing (face shield,heavy gloves and apron, etc.) whenworking on a hot engine.

Open the drain valve and drain offsome fuel into a container. Use a strapwrench to remove the filter cartridgetogether with the bowl.

126 Maintenance

2 Separate the filter and the bowl.

NOTE! Always dispose of fuel ac-cording to Federal or local regulations.Take all waste fuel to a recycling orwaste collection center.

3 Clean and dry the bowl. Attach it to anew filter. Use new seals at both bowland filter head joint. Install both onthe filter head in the vehicle.

CAUTION

Never fill filter with fuel before in-stalling. Contaminated fuel causesaccelerated wear to fuel systemcomponents.

4 To eliminate air from the filter, operatethe primer pump to draw fuel and fillthe filter.

5

WARNING

Do not work near the fan with theengine running. The engine fan canengage at any time without warn-ing. Anyone near the fan when itturns on could be seriously injured.Before turning on the ignition, besure that no one is near the fan.

Start the engine and check for leaks.Correct any leaks with the enginestopped.

Maintenance 127

Changing the Secondary Fuel Filter


1

WARNING

Keep yourself clear of all hot en-gine parts and/or fluids. A hotengine and/or fluids can cause seri-ous burns.

Clean around the fuel filter. This isimportant — if dirt mixes with thefuel from this filter, it will end up inthe injection system.

2


Remove the filter element. Dispose ofit in a safe and responsible manner.

128 Maintenance

3 Wet the seal on the new filter withclean engine oil or fuel.

4

CAUTION

Never fill filter with fuel before in-stalling. Contaminated fuel causesaccelerated wear to fuel systemcomponents.

Spin on the new filter onto the filterhead until it contacts the seal fully (noside movement evident). Tighten anadditional 1/2 to 3/4 turn by hand. Donot overtighten!

5 To eliminate air from the filter, operatethe primer pump to draw fuel and fillthe filter.

6

WARNING


Start the engine and check for leaks.Correct any leaks with the enginestopped.

Maintenance 129

Bleeding the Fuel SystemThe fuel system will have to be bled if:

• The tank has been emptied of fuel.

• The engine has not been running forsome time. (See also page 36 for oilpressure preparation).

• Service work has been done on thefuel system, for example cleaning orreplacing fuel filter elements.

• The engine is new or rebuilt.

NOTE! It is very important to maintainhigh cleanliness when working in the fuelsystem. If dirt is mixed in with the fuel af-ter the filters, it will cause damage to theinjectors. Dirt can also cause air leakagesthat rob the engine of power.

130 Maintenance

Bleeding D12 Engine


1

WARNING


Clean well around the bleed nippleson the fuel filter head and the cylinderhead.

2


Maintenance 131

Remove the protection cap from thefilter bleed nipple. Connect a transpar-ent 5/16 in. (8 mm) plastic hose to thenipple. Open the nipple with an 11mm wrench and pump the hand primeruntil clean, air-free fuel flows out ofthe hose. Tighten the bleed nipplewhile fuel is still flowing.

3 Remove the hose and install the pro-tection cap on the nipple.

4 Remove the protection cap from thecylinder head bleed nipple. Connectthe plastic hose to the nipple. Openthe bleed nipple with an 11 mmwrench and pump the hand primer un-til clean, air-free fuel flows out of thehose. Tighten the nipple while fuel isstill flowing.

5

WARNING


Start the engine and run it at an in-creased idle speed for approximately 5minutes to remove any remaining airin the system. Check the fuel systemfor leaks.

T0008116

T0008115

132 Maintenance

Bleeding D7 Engine


1

WARNING


Clean well around the bleed nipple onthe fuel filter head.

2 Make sure the ignition is ON. The fuelsystem is not activated with the igni-tion key switch off.

3


Maintenance 133

Remove the protection cap from thefilter bleed nipple. Connect a transpar-ent 5/16 in. (8 mm) plastic hose to thenipple. Open the nipple with an 11mm wrench and pump the hand primeruntil clean, air-free fuel flows out ofthe hose. Tighten the bleed nipplewhile fuel is still flowing.

4 Remove the hose and install the pro-tection cap on the nipple.

5

WARNING


Start the engine and run it at an in-creased idle speed for approximately 5minutes to remove any remaining airin the system. Check the fuel systemfor leaks.

W2003174

134 Maintenance

Draining Water from the Fuel Tank


Water accumulates in the fuel tank in theprocess of air entering the tank and watervapor condensing. This water will collect inthe bottom of the tank and should be emp-tied out regularly.

To minimize the water vapor condensinginside the tank, the fuel level should bekept high when the vehicle is parked. Al-ways fill up the tank at the end of the tripto minimize the amount of air in the tank.

WARNING

Do not service any part of the fuel sys-tem while smoking or while in thepresence of flames, sparks or hot sur-faces. Failure to follow these precautionscan result in fire and personal injury.

NOTE! When draining the fuel tank, col-lect the waste in a fuelproof container. Takethe drained fuel and water to a recycle orwaste management center.

To drain the tank, place a container underthe tank. Remove the plug in the bottom.Drain fluid until there is only fuel comingout. Install the plug and check for leaks.

NOTE! Always dispose of fuel accordingto Federal or local regulations. Take allwaste fuel to a recycling or waste collec-tion center.

Maintenance 135

Transmission and Rear Axle MaintenanceTransmission

GeneralTransmissions should not be operated con-sistently at temperatures above 250�F(120�C). If the temperature reaches 285�F(140�C), stop the vehicle to let the tempera-ture go down (see the vehicle Operator’sManual for information on the optionaltransmission temperature gauge). Operatingtemperatures above 250�F (120�C) increasethe lubricant’s rate of oxidation and shortenits effective life.

If the transmission oil temperatures areconsistently high, change oil more often orinstall an oil cooler. With lengthy or contin-uous driving at altitudes of more than 6,000ft (2,000 m) above sea level, more frequentoil changes will be necessary.

NOTE! Always dispose of oil according toFederal or local regulations. Used oildisposed of in nature or waterways contam-inates our drinking water and kills wildlife.Take all used oil to a recycling or wastecollection center.

W4001387

136 Maintenance

Oil Quality

CAUTION

Use only the specified type of singleweight oils. Do not use multigrade oilsor EP gear oils (for example axle lubeoil such as GL-5 gear oils) as they maydamage components.

Monograde motor oils or transmission oiltype API GL-1 are recommended for trans-missions. Choose the correct viscosity forthe outside temperature the vehicle will beoperated in. See page 164 for the beginningof viscosity charts.

If using synthetic base oils, the change in-terval goes up to 250,000 miles (400,000km) or 500,000 miles (800,000 km), if us-ing the manufacturer approved brand of oil.

Oil FilterOil filters should be changed at the sametime as the oil. Also, make sure that mag-netic bottom plugs are cleaned beforeinstalling. Change the filters in accordancewith the manufacturer’s Operator’s Manual.

Maintenance 137

DriveShaft

If the driveshaft universal joints are notlubricated properly, they can be dam-aged to the point of the driveshaftseparating from the vehicle. Driveshaftseparation may cause loss of control ofthe vehicle resulting in severe personalinjury or death.

Make sure grease is purging from all fourends of the universal joint. If the universaljoint can not be properly lubricated, replaceit.

Rear Axle

GeneralNOTE! Most rear axles today are run witha synthetic base oil. The Volvo rear axlesare an exception. Do not use a syntheticbase oil in Volvo rear axles. Seals will de-teriorate and leaks will develop.

Rear axles should not be operated if the oiltemperature exceeds 250�F (120�C).Choose the correct viscosity for the temper-ature the vehicle is operated in. See page161 for a beginning of viscosity charts.

138 Maintenance

Steering and Brakes Maintenance

Steering SystemExcessive play in the steering system ischecked by turning the steering wheelwhile the engine is stopped. With the frontwheels pointing straight ahead, turn thesteering wheel until the front wheel startsmoving. Then, turn the steering wheel theother 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 steeringlinkage for looseness, wear, etc. Make nec-essary repairs before driving the vehicle.

W6000830

Power Steering ReservoirThe power steering fluid reservoir is filledwith Automatic Transmission Fluid (ATF)Dexron® III for the power steering system.Change fluid every 150,000 miles(240,000 km). Change filter every year ormore often if necessary.

If the fluid has darkened, it indicates thatthe power steering system is running hotterthan normal and the fluid is overheating.Take the vehicle to a Volvo Truck dealerfor troubleshooting the overheating and tohave the fluid changed.

W6000874

Steering Linkage Wear CheckIf the dial indicates a reading of more than0.060 inch (1.52 mm), tie rod end must bereplaced.

W6001446

Maintenance 139

Brake Safety Information

Failure to properly maintain the brakesystem can result in compromised brakeefficiency and may lead to loss of con-trol of the vehicle resulting in severepersonal injury or death.

Do not use replacement parts anywherein the brake system unless it conformsexactly to original specifications. A non-conforming part in your vehicle’s brakesystem could cause a malfunction, lead-ing to loss of control of the vehicleresulting in severe personal injury ordeath.

Do not release the parking brake or at-tempt to move the vehicle until brake airpressure in both circuits is at least 100psi (690 kPa). Failure to follow this pro-cedure may lead to uncontrolled vehiclemovement and cause severe personal in-jury or death.

The brake system is a critical vehicle safetysystem. For your safety and for thosearound you, follow the recommended pre-ventive maintenance checks. If anyproblems occur, have them investigated im-mediately by an authorized service facility.

Drain the air system tanks at the recom-mended intervals. If condensationaccumulates, moisture can enter thebrake system air valves, causing corro-sion or clogging. The safety of the brakesystem could be compromised, leadingto an accident causing severe personalinjury or death.

Before working on a vehicle, set theparking brakes, place the transmission inneutral, and block the wheels. Failure todo so can result in unexpected vehiclemovement and can cause serious per-sonal injury or death.

CAUTION

Do not use penetrating oil, brake fluid orwax-based oils in the air system. Thesefluids may cause severe damage to airsystem components.

140 Maintenance

Air Tanks

WARNING

When draining the air tanks, do not lookinto the area of the draining air. Dirt orsludge particles may be in the air streamthat could cause eye injury.

Air tanks should be drained daily. Makesure the drain cocks close properly afterdraining. Empty moisture from air tanks bypulling the drain valve wire. The tanksshould be checked for condensation fluid,even if an automatic drain valve is installed.

It is very important that the air system iskept clean. Air reservoirs should be draineddaily or even twice a day on very hot days.Daily drainage expels any condensation inthe air reservoirs. If sludge or oil is foundin the drainage, the air compressor shouldbe checked for proper operation.

If an excessive amount of fluid is drainedout of the tanks (even when drained daily)have the system checked for possible prob-lems with the air dryer.

W5000601

Air DryersAir dryers have a regeneration system thatcleans out the accumulated moisture buteventually the drying medium will be filledup. Change the dryer cartridge when morewater than usual is noticed at the daily tankdrainings. The volume of daily drain waterwill change depending on temperature, geo-graphical location and how much thebrakes are used.

Dryer manufacturers recommends changingthe cartridge every 2 to 3 years but the in-tervals need to be adjusted for vehicleapplication. In hot, coastal climates, the car-tridge may have to be changed every year.

Maintenance 141

Brake Slack Adjusters and Cam

Before checking the slack adjusters, setthe parking brakes, place the transmis-sion in neutral and block the wheels.Failure to do so can result in unexpectedvehicle movement and can cause seriouspersonal injury or death.

To check the slack adjusters for properthrow, use a breaker bar to lever the slackadjuster out. Measure the distance of thetravel. It should not exceed 1 to 1 1/4 in.(25 to 30 mm) for a 6 in. slack adjuster andshould not exceed 3/4 to 1 in.(20 to 25 mm) for a 5 1/2 in. slack ad-juster. Also make sure that the length of theslack adjuster is the same on an axle.

W5000613

Brake Linings

Before measuring the brake linings, setthe parking brakes, place the transmis-sion in neutral and block the wheels.Failure to do so can result in unexpectedvehicle movement and can cause seriouspersonal injury or death.

Measure the brake lining thickness. If thebrakes are equipped with backing plates,measure through the inspection holes in theplate. Reline the brake shoes if the liningthickness is 1/4 in. (6 mm) or less at themiddle of the shoe.

Check the brake drums for any visiblecracks or signs of oil or grease.

W5000610

142 Maintenance

Check Valves

Before working on or inspecting the ve-hicle, set the parking brakes, place thetransmission in neutral and block thewheels. Failure to do so can result in un-expected vehicle movement and cancause serious personal injury or death.

Follow the procedure below to check outthe air tank check valves at least once ayear. This is to see if air pressure is main-tained in the tanks when the air pressure isdepleted in the supply tank (wet tank).

NOTE! The check valves should bechecked at least once per year.

1 Chock the rear wheels.2 Let the compressor build up air pres-

sure to the governor cut-off.3 Bleed the air pressure from the supply

tank (wet tank).4 Check the air pressure gauges on the

instrument panel to see if the pressureis maintained in both primary and sec-ondary air tanks.

5 Any bleed-off from one or both of thetanks indicates a defective checkvalve; replace valve.

6 Repressurize the system and removethe wheel chocks.

WARNING

To prevent personal injury, always drainthe air supply from the vehicle beforeattempting to repair or replace a compo-nent. Wear eye protection and take carenot to get fingers caught in the slack ad-justers when spring brakes are applied.

Compressed air components can separateviolently during disassembly if air pres-sure is present. Before servicing any partof the brake air system, completely re-lease the air pressure. Failure to do socan result in serious personal injury ordeath.

Maintenance 143

Air System PressureAir pressures in the two circuits are moni-tored by two pressure gauges on the rightside of the instrument panel. The gauge forthe primary (rear) brake circuit is markedwith an “R” within a symbol and the gaugefor the secondary (front) brake circuit ismarked with an “F” within a symbol. Thetwo pointers should register equal or nearlyequal pressure. By observing the gaugepointers, the operator is forewarned in theevent of a pressure drop in either or both ofthe circuits, and also may readily identifythe specific circuit.

Before operating the vehicle, check the airgauges which indicate air pressure. Theyshould not register less than 105 psi(725 kPa). Maximum pressure at any timeshould not exceed 150 psi (1035 kPa).

W3000609

Air Tubing and HosesAll compressed air tubing and hoses needregular inspection. Check for signs of wearand that the routing is not near parts thatcan cause damage.

Have any damaged tubing or hoses re-placed by your local Volvo Truck dealer.

W3000838

144 Maintenance

Electrical System Maintenance

Battery Care

WARNING

Battery posts, terminals and relatedaccessories contain lead and lead com-pounds, chemicals known to the State ofCalifornia to cause cancer and reproduc-tive harm. Wash hands after handling.

The electrolyte level on maintenance freebatteries cannot be checked. Periodically,the condition and the state-of-charge ofeach battery should be checked by a VolvoTruck dealer. Maintenance free batteries donot require any attention other than keepingthem clean and firmly clamped in place intheir respective trays. Keep the cable con-nections clean and tight. Check the batterystate-of-charge indicators periodically todetermine battery condition.

Check for worn cables at every major in-spection. Replace worn cables. Checkbattery terminals for cracks.

When disconnecting battery terminals, al-ways disconnect the ground terminal first.When reconnecting, always connect theground terminal last.

W3002368

WARNING


LightingCheck the lights on the vehicle daily. Re-place burnt out bulbs. See next page for alisting of bulb types. Replace any broken orcracked reflectors.

Headlights should be checked for aim atleast once per year.

W3000953

Maintenance 145

Bulb Replacement List

Bulb Number Amps

Headlamp, Hi/Low Beam 9007 5.1/4.3

Back-Of-Cab Lamp 1156 2.1

Back-up Lamp 1156 2.1

Cab Marker Lamp (w/o sunvisor) 67 0.59

Driving Lamp H9415 2.93

Fog Lamp H9420 3.9

Instrument Telltale Lamps 3919844 (Volvo) 0.125

Door Courtesy Lamp 67 0.59

All Overhead Dome/Spot Lamp (incandes-cent)

1156 (dome)67 (spot)

2.10.59

Overhead Fluorescent Lamp PL-L 24W/827/4PP (Philips)16944 (GE)

2.0

Reading Lamp Under Bunk Storage 1057 (P21W) 0.97

Combined Reading/Spot Lamp Under BunkStorage

1057 (P21W)(reading)67(spot)

0.970.69

Luggage Compartment Lamp 1156 2.1

Side Repeater 1156 2.1

Turn Signal Lamp (front) 3357 2.2

Turn Signal/Stop Lamp (rear) 1157 2.1

Rear Marker Lamps/Licence Plate Lamp 1157 0.59

Work Center Lamp (fluorescent) PL-L 24W/827/4PP (Philips)16944 (GE)

2.0

146 Maintenance

Tires, Wheels and Hub MaintenanceWheel Safety Information

Do not attempt to repair wheels or tiresunless you are trained and equipped todo so. Wheel and tire assemblies cannotbe worked on without proper tools andequipment. Failure to follow this maylead to serious personal injury or death.

Failure to properly torque-tighten thewheel nuts can result in the breakage ofwheel studs and the subsequent loss ofwheels. Loss of vehicle control and seri-ous personal injury or death can occur.

Do not use oil or grease on studs ornuts. The tightening torque is affectedand can lead to incorrect clamping loadsbetween the rim and hub. This couldlead to a loss of the wheel. Loss of vehi-cle control and serious personal injury ordeath can occur.

Do not install regrooved, retreaded or re-paired tires on the steering axle(s). Theycould fail unexpectedly and cause theloss of vehicle control, leading to seri-ous personal injury or death.

Do not use mismatched wheel compo-nents. If they do not exactly match theoriginal design specifications, they maycause failure or separation leading to anaccident causing serious personal injuryor death.

Do not install tires with a load ratingthat is less than stated on the Certifica-tion Label in the door frame. The tirecould be unintentionally overloaded,leading to an accident, causing seriouspersonal injury or death.

Do not use mismatched tires on thesame axle. Always use the same type(radial or bias ply) or size. Mixing tireson the same axle will affect the road-holding and can lead to an accidentcausing serious personal injury or death.

Maintenance 147

Wheels

Before checking the wheels, set theparking brakes, place the transmission inneutral and block the wheels. Failure todo so can result in unexpected vehiclemovement and can cause serious per-sonal injury or death.

Wheels must be serviced only by a qual-ified technician. Do not do this workyourself. Inflated tires on wheels containcompressed air and if suddenly released,do so with an explosive force. Seriouspersonal injury or death can occur.

Check wheels for signs of rust streaksaround the wheel nuts. This indicates loose-ness (steel rims). Inspect all types of rimsfor cracks. Cracks can appear in manyplaces but typically radiate out from wherea load is applied. Inspect closely aroundwheelnuts, handholes and insidecircumference.

W7000445

Wheel Nut TighteningAfter the initial tightening, retighteningmust be made within the first 500 miles(800 km). After the first retightening, onlynormal inspection of nut tightness isneeded.

Check front and rear wheel nut tightnesswith a torque wrench. All disc wheels forVolvo vehicles have a tightening torque of450 ft-lb (610 Nm). Tighten the nuts in thecorrect sequence. For spoke wheels, checkthe manufacturer’s specifications. Inspectbolts and nuts for signs of wear or cracks.Make sure that the bolts are not bent.

W7000436

148 Maintenance

Failure to properly torque-tighten thewheel nuts can result in the breakage ofwheel studs and the subsequent loss ofwheels, loss of vehicle control and seri-ous personal injury or death.

This check tightening is particularly impor-tant when rims or brake drums are newlypainted. Paint can flake off from these sur-faces, causing the nuts to lose their gripand the wheel to loosen.

W7000774

8 and 10–stud wheelnut tighteningsequence.

Tire Inflation and Wear

Before checking the tires, set the park-ing brakes, place the transmission inneutral and block the wheels. Failure todo so can result in unexpected vehiclemovement and can cause serious per-sonal injury or death.

WARNING

Check tire pressure when the tire iscool. Never bleed the air from hot tires.Increased tire pressure measured in a hottire is normal. Low pressures may causeside wall flexing may result in increasedheat leading to tire failure.

Measure the tread depth. The depth shouldnot be less than 4/32 in.(3.2 mm) on front tires and not less than2/32 in. (1.6 mm) on drive tires.

It is important to have the wheels correctlyaligned. Check for uneven tire wear fre-quently. Uneven tire wear is a sign ofwheels out of alignment. Refer to page 182for examples of typical tire wear.

W7000773

Maintenance 149

Do not operate the vehicle with underin-flated tires. Always keep your tiresinflated to the manufacturer’s recom-mendation. Increased flexing in the tiresidewall produces heat. The heat canbuild to the point of blowing the tire outcausing an accident and lead to seriouspersonal injury or death.

Remove stones lodged in ribs or in betweendouble-mounted wheels. Check the tirepressure and leak-test the valve stems.

W7000437

Front Wheel HubsThe front wheel hubs can be filled with oneof several types of oil. Motor oil should beSAE 30 or 15W40. The oil can be eitherpetroleum based or synthetic (syntheticshould not be used for the Volvo axle).Axle oil, API GL-5, SAE 75W-90, can alsobe used.

There are no set change intervals for hublubrication. The only requirement is that ifthe hub is opened, the lubricant must bechanged.

Failure to keep wheel bearings properlyadjusted may result in accelerated tirewear, poor handling and, in extremecases, wheel separation from the hub orfrom the spindle.It is important that wheel bearings arechecked and adjusted regularly. Failureto properly maintain these bearings canultimately result in loss of vehicle con-trol and cause serious personal injury ordeath.

W7000438

150 Maintenance

Chassis MaintenanceSpringsNOTE! This work is best performed by aVolvo Truck dealer or other service outlethaving the proper equipment.

The spring package is fastened to the axlebeam with U-bolts. It is important that theU-bolt nuts are properly tightened. The nutsmay loosen up with time. Severe roads andservice will loosen them faster. Loose U-bolts can cause springs to break, axlemisalignment, hard steering and abnormaltire wear.

Do not operate the vehicle if the U-boltsare loose. If the U-bolts are loose, theaxle is not properly secured to the sus-pension. This could cause loss of controlof the vehicle leading to an accident re-sulting in personal injury or death.

The U-bolt nuts need to be retightened tothe proper torque, both on front and rearaxles, at 15,000 miles (24,000 km). Torquefor the front axle is 310 ft-lb (420 Nm) andfor the rear axle it is 370 ft-lb (500 Nm).

W6000875

Maintenance 151

Spring Bushings


When lubricating the springs, lift the axleoff of the floor, suspend the frame with axlestands and lower the axle (or lift the frontby lifting under the front engine crossmem-ber.) The spring bushings are now in theposition where grease can be added to thecontact surfaces. If the spring bushings aregreased without taking the load off, highwear and lower lifetime will occur becauseof no grease reaching the contact surfaces.

If the vehicle is being driven in severe cli-mates with a lot of wet, slushy, highlydusty roads, or in off-road service, increasethe frequency of spring bushing lubrication.

W7000449

T-Ride Equalizer BeamsThe Volvo T-Ride suspension has equalizerbeams between the tandem axles. The beambushing needs to be lubricated at the normallube intervals for normal highway driving.If the vehicle is being driven in severe cli-mates with a lot of wet, slushy, highlydusty roads, or in off-road service, increasethe frequency of lubrication. If driving insevere duty, where water may enter thebushing, daily lubrication may be necessary.

W6000838

152 Maintenance

Cab MaintenanceDoorsThe door lock mechanism should begreased annually using white grease. Lubri-cate the door lock cylinder with liquidgraphite annually, or more often in climateswith a lot of snow and salt on the roads.Coat the door stop arm with white greaseannually.

On wet and salted roads, roadspray can en-ter the door lock key cylinder. Lubricate thecylinder with liquid graphite annually ormore often if necessary.

The door hinge pins are treated at manufac-turing and then sealed. No lubrication isnecessary.

To keep the door rubber moldings and sealsaround the windows in good working orderand to prevent them from freezing shut dur-ing the cold season, occasionally spray on asilicone compound.

W8000949

HoodThe hood latch mechanism should begreased with white grease yearly. If themechanism is hard to work or binds, thelatch should be cleaned before greasing.

W8000888

Maintenance 153

RustprotectionThe rustprotection applied when the cabwas produced is adequate for normal useand service. If an extension of the cab rust-protection is desired or if the vehicle is usedin a severe application, it is recommendedthat cavity wax is re-applied every 3rd year.

Cab Air FiltersAir going into the cab passes a filter lo-cated on the right, front side of the cab.Remove the filter and clean with an air gun(no more than 20 psi pressure) after 40,000miles (64,000 km), (in dusty conditions asoften as every 10,000 miles [16,000 km]).Make sure the air stream is directed fromthe inside out.

The filter should not be cleaned and reusedmore than once. Replace with a new filterafter maximum 70,000 miles (110,000 km),or earlier if driving in dusty conditions. Aclogged filter decreases the efficiency of theair conditioning system. W8002474

If the vehicle is equipped with a sleeperheater-A/C, there is a filter for the recircu-lating air. This is located behind thepassenger seat on the bunk support. The fil-ter should be checked and cleaned after40,000 miles (64,000 km), (in dusty condi-tions as often as every 10,000 miles [16,000km]). Clean as the cab air filter. Replacefilter after 100,000 miles (160,000 km).

To inspect or to change the filter, openbunk lid and pull out filter. W8002473

154 Maintenance

Lacquer and Brightwork Care

PaintCabWash all exterior painted surfaces fre-quently to remove dirt. It is especiallyimportant to wash off salt-laden snow andice during the cold season. A mild detergentcan be used but avoid strong detergents.

NOTE! Do not aim the water jet directly atdoor and window seals or door locks. Iflocks are filled with water, use compressedair to clean the water out and then applyliquid graphite. Be especially careful ofleaving water in locks or around seals dur-ing freezing weather.

Wet the surface with water to loosen dirt.The use of steam or high pressure waterwill help in removing loose dirt. Wash thesurface with a sponge using a lot of waterto flush away dirt. Dry the surface with atowel or chamois. Do not wait until it isdry as dry-dusting will scratch the surface.

Apply a coat of wax regularly. This willhelp the paint and other surfaces keep theirluster. If the surface gets dull, use a restor-ing cleaner specially designed for this.Clean off all tar spots and tree sap beforewaxing.

When the vehicle is new, allow enoughtime for the paint to cure. Wait about 30days after the date of manufacture beforeputting on the first coat of wax. Never waxon a hot day under the sun and do not ap-ply too much pressure with a buffer asburns may develop from the friction.

Maintenance 155

ChassisKeep the chassis free from buildup of dirt.Make sure the chassis is cleaned before themaintenance inspections to help spottingleaks, etc. As salt can be part of the roadsludge during the cold season, removebuildup of snow and ice so it does not pro-mote corrosion. At the end of the coldseason, thoroughly flush away all collecteddirt from the chassis.

Stainless SteelStainless steel will rust if exposed to saltfor too long. Wash frequently, especiallyduring the cold season, to remove salt-laden snow and ice. If rust appears, washthe surface and use a rubbing compound toremove the rust. Apply a coat of wax as afinish (do not wax parts that get hot, suchas exhaust pipes, etc.).

NOTE! Never use steel wool to clean stain-less steel. Pieces of the steel wool break offand give rust stains on the surface.

156 Maintenance

ChromeChromed surfaces will rust if they are notprotected. This is especially important dur-ing the cold season when roads are saltedor in coastal areas where the salt level inthe air is high.

Clean chrome surfaces with clean water. Ifthe surface has heavy dirt or tar spots, usea tar remover. To remove rust spots, use anon-abrasive chrome cleaner and apply acoat of wax as a finish (do not wax partsthat get hot, such as exhaust pipes, etc.).

NOTE! Never use steel wool to cleanchrome. Pieces of the steel wool break offand give rust stains on the surface.

AluminumUnprotected aluminum surfaces will forman oxide layer if not maintained. This is es-pecially important during the cold seasonwhen roads are salted or in coastal areaswhere the salt level in the air is high. Cleanwith steam or high pressure water. Use amild detergent if the dirt is heavy. Rinsewell.

Clean aluminum surfaces with warm water.If the surface has heavy dirt or tar spots,use a tar remover. To prevent spotting, wipealuminum surfaces dry after washing.

UpholsteryClean vinyl and cloth upholstery with lightbrushing or vacuuming. If heavily soiled,use warm water with mild soap such assaddle or oil soap.

Maintenance 157

Lubrication, VNChassis Lubrication

Before working on or servicing a vehi-cle, set the parking brakes, place thetransmission in neutral and block thewheels. Failure to do so can result in un-expected vehicle movement and cancause serious personal injury or death.

General lubrication includes lubricating allthe grease fittings in the drivetrain, frontand rear suspensions, power steering, andfront axle, using a grease gun.

Grease the chassis every 15,000 miles(24,000 km). However, if the vehicle is in ademanding application or running in a dirtyor corrosive atmosphere, adjust the lubrica-tion intervals to reflect heavy-duty use. Forexample, if driven in heavy stop-and-gotraffic with a lot of maneuvering, the lubri-cation intervals should be every10,000 miles (16,000 km) or less.

All lubricating points are found on thechassis lubrication chart on the next page.

Lubricating GreaseUse grease with a lithium base with EP ad-ditives and a consistency of NLGI No.2.The No.2 consistency is suitable for mosttemperatures. Use NLGI No.1 or No.0 forextremely low temperatures.

Care should be taken not to use any greaseother than one with EP additives for thedriveshaft. Do not use any solid lubricants,such as graphite, copper or molybdenumdisulfide.

Lubrication ProcedureMake sure the grease fittings are cleanedoff before filling grease. Dirt on the fittingthat is not cleaned off is pushed into thepart together with the new grease. Alwaysfill grease to the point where old grease andcontaminants are forced out from the partand only new grease comes out. If newgrease cannot be filled so old grease isflushed out, the part needs to be checkedfor problems. If a fitting does not acceptlubrication due to damage or internal stop-page, replace it with a new fitting.

NOTE! Think of greasing the same way asan oil change. All old grease needs to comeout and be replaced with new grease.

Where rubber or plastic parts are involved,do not heat part for better grease applica-tion.

Remove excess grease from fittings, shack-les and other surfaces.

NOTE! Always grease a Volvo front axlewith the wheels on the ground.

158 Maintenance

Lubrication ChartSpring hanger (2)

Note 8

Coolant level

Note 1Slack Adjuster & Brake

Cam (4) Note 9

Power steering fluid

Note 2Steering gear (1)

Note 10Kingpin, upper & lower (4)

Note 11

Wheel bearings

Note 3Tierod (2)

Note 12

Engine oil & filter

Note 4Spring Hanger (4)

Note 8Clutch Cylinder Fluid

Note 5U-Joint (1)

Note 13Manual transmission

Note 6U-Joint (1)

Note 13

U-Joint (1)

Note 13Rear axle

Note 7Slack Adjuster & Brake

Cam (4) Note 9

T-Ride Bogie Beam (2)

Note 14

Slack Adjuster & Brake

Cam (4) Note 9

Rear axle

Note 7

W1000137

Grease Coolant

Hub Oil Aut. Transm. Fluid

Engine Oil Man. Transm. Oil

Hydraulic Oil Rear Axle Oil

There are notes foreach type of lubrica-tion on the followingpages. Read thesenotes before select-ing a lubricant.

Steering Fluid Brake Fluid

Maintenance 159

Lubrication Chart Notes1 Add if necessary. Only use pre-mixed

clean water and antifreeze in a 50/50mix.Add only the same type antifreeze,that is: extended life or standard.

2 Check the fluid in the reservoir withthe dipstick. Add if necessary. UseATF Dexron® III. Change fluid every150,000 miles (240,000 km). Changefilter every year.

3 There is no set change interval.Change the oil (or grease) only in con-nection with work on the hub or if dirtis found in the lubrication. Motor oilshould be SAE 30 or 15W40. The oilcan be either petroleum based or syn-thetic (synthetic should not be used forthe Volvo axle). Axle oil, API GL-5,SAE 75W-90, can also be used.

4 Change the oil every 10,000 or 12,000miles (16,000 or 19,000 km) for D7engine or 15,000 miles (24,000 km)for D12 engine when using API CF-4,CG-4 or CH-4 oil. Change the oil ev-ery 15,000 miles (24,000 km) for D7engine or 25,000 miles (40,000 km)when using VDS or VDS-2 oil.

5 Check that the fluid is at the correctlevel. If needed, add fluid using brakefluid DOT 4. Fluid should be replacedevery 2 years.

6 Use a mineral or synthetic oil. Checkoil level periodically. Level should beto the bottom of the inspection hole.See page 164 for oil types.

7 Check the oil level in the rear axles.The level should be level with the in-spection hole. Add if necessary. Seepage 166 for oil types.

8 Use a lithium based grease with speci-fication API NLGI No. 2. Whenlubricating the springs, lift the axle offof the floor, suspend the frame withaxle stands and lower the axle. Thespring bushings are now in the posi-tion where grease can be added to thecontact surfaces.

9 Use a lithium based grease with speci-fication API NLGI No. 2. Useliberally in the slack adjuster. Makesure the grease purges through the sealon the brake cam.

NOTE! If the brake cam seal does notpurge, make sure the inner seal doesnot purge into the brake drum andbrake linings.

10 Use a lithium based grease with speci-fication API NLGI No. 2. Only use ahand operated grease gun. An air oper-ated grease gun will damage the seal.

11 Use a lithium based grease with speci-fication API NLGI No. 2.

NOTE! Always grease a Volvo frontaxle with the wheels on the ground.

NOTE! To grease non-Volvo axles,they are typically greased with thewheels on the ground. Consult withthe axle manufacturer for the latestrecommendation.

160 Maintenance

12 Use a lithium based grease with speci-fication API NLGI No. 2.

NOTE! Volvo axles may use agreased-for-life tierod. No provisionsfor adding grease are available.

13 Use a lithium based grease with EPadditives to specification API NLGINo. 2.

NOTE! Make absolutely sure thatgrease purges out of all four seals ofthe U-joint.

14 Use a lithium based grease with EPadditives to specification API NLGINo. 2. Make sure the grease purgesout of both the inner and outer seals.If necessary, adjust the lubricationschedule to include greasing the bogiebearing as often as daily, in applica-tions where the bogie runs in corrosiveconditions or is submerged in water.

Maintenance 161

Viscosity and Capacity Tables

Volvo Engine D7C

For oil change intervals, see page 68

First oil and filterchange

After 1 month or6,000 miles(10,000 km)

Capacity (including filters)

D7C service 22 quarts (21 liters)

Oil volume be-tween high andlow on dipstick

7.0 quarts (6.5liters)

W1000144

1 Only completely syntheticand/or VDS/VDS-2 oils.

2 Only VDS-2 oils.

Volvo Engine D12

For oil change intervals, see page 65

First oil and filterchange

After 1 month or6,000 miles(10,000 km)


D12 service 37 quarts (35 liters)


7.5 quarts (7.0liters)

W1000144

1 Only completely syntheticand/or VDS/VDS-2 oils.

2 Only VDS-2 oils.

162 Maintenance

Cummins Engine M11 & N14

For oil change intervals, see the manu-facturer’s Operator’s Manual


M11, service 39 quarts (37 liters)

M11, oil volumebetween high andlow on dipstick

7-9 quarts(6.5-8.5 liters)

N14, service 41 quarts (39 liters)

N14, oil volumebetween high andlow on dipstick

8-9.5 quarts(7.5-9 liters)

W2002132

Cummins Engine ISM & ISX



ISM, service 39 quarts (37 liters)

ISM, oil volumebetween high andlow on dipstick

7-9 quarts(6.5-8.5 liters)

ISX, service 41 quarts (39 liters)

ISX, oil volumebetween high andlow on dipstick

8-9.5 quarts(7.5-9 liters)

W2002132

Maintenance 163

Detroit Diesel Series 60



11.1L, service ... 38 quarts(36 liters)

12.7L, service ... 38 quarts(36 liters)


6 quarts(5.5 liters)

W2002131

Cooling System Capacity*

FE ...................... 34 liters(9 US gal.)

WG, D7 ............. 36 liters(9.5 US gal.)

WG, D12 ........... 42.3 liters(11.2 US gal.)

WX, WXLL ...... 42 liters(11 US gal.)

WI, AC .............. 49.2 liters(13 US gal.)

VN, D12 ........... 39 liters(9.8 US gal.)

* approximate capacities

164 Maintenance

Clutch Hydraulic System

Clutch systemfluid ...................

brake fluid accord-ing to DOT 4(SAE J 1703)

Replacement inter-val ......................

every two years

Meritor Transmission 9,10 and 13–speed


Capacity:

9, 10 and 13-speed ..............

10.5 quarts(10.0 liters)

W4000878

Fuller Transmission 9,10, 13, 15 and 18–speed

For oil change intervals, see the manu-facturer’s Oparator’s Manual

Capacity:

9-speed .............. 13.5 quarts(12.0 liters)

10, 13, 15 and 18-speed .................


W4002530

Maintenance 165

Spicer Transmission PSO-175–18A

For oil change intervals, see the manu-facturer’s Operator’s Manual.

Capacity:

PSO-175-18A 15.0 quarts(14.0 liters)

W4000878

Allison Automatic Transmission

For oil change intervals, see the manu-facturer’s Operator’s Manual.

Approximate Capacity:

MD3560P 5-speedMD3060P 5-speed


HT740D 4-speedHT740RS 4-speed


HT750DR 5-speedHT754CR 5-speed


HD4060P 5-speedHD4560P 5-speed


Oil drain plugtorque ................

18-24 ft-lb (25-32Nm)

W1000143

1) “Arctic” as defined by MIL-L-46167B

NOTE! Fluid may requirechange sooner than listed intervals,depending on operating condi-tions. Fluid must also be changedwhenever there is evidence of dirtor high temperature condition asindicated by discoloration, strongodor or fluid analysis.

166 Maintenance

Dirona Tandem RT46–157


Capacity:

RT46-157, fronttandemRT46-157, reartandem

16 quarts(15 liters)14 quarts(13 liters)

W4000881

1) Select viscosity from the tableabove. Temperatures refer to sta-ble ambient temperature readings.There is no upper limit to theseoutside temperatures but the axlesump temperature MUST NEVEREXCEED 250�F (120�C).

Volvo Tandem CT EV87

Oil type:

Petroleum basedoil ......................

API-GL5, MIL-PRF-2105E

First oil change After one month or6,000 miles(1, 000 km)

Normal oil changeinterval ..............

every 12 month or75,000 miles(120,000 km)

Synthetic lubri-cant ....................

NOT USED

Capacity:

front tandem ...... 21.0 quarts(20.0 liters)

rear tandem ....... 9.5 quarts(9.0 liters)

W4000880

1) For very hard or continuous op-eration above an altitude of 6,000ft (2,000 m) above sea level, a vis-cosity of SAE 140, SAE 80W/140or SAE 85W/140 is recommendedfor use instead of SAE 90.

Maintenance 167

Meritor Single RS23–160 & 185Meritor Tandem RT40–145


Capacity:

RS23-160 .......... 20 quarts(19 liters)

RS23-185 .......... 23.5 quarts(22.5 liters)

RS23-186 .......... 23.5 quarts(22.5 liters)

RS25-160 .......... 23.5 quarts(22.5 liters)

RS26-185 .......... 23 quarts(22 liters)

RS30-185 .......... 23 quarts(22. liters)

RT40-145, fronttandemRT40-145, reartandem

15 quarts(14 liters)13 quarts(12 liters)

W4000881

1) Select viscosity from the tableabove. Temperatures refer to sta-ble ambient temperature readings.There is no upper limit to theseoutside temperatures but the axlesump temperature MUST NEVEREXCEED 250�F (120�C).

168 Maintenance

Eaton Single 23080, 23105 & 26105Eaton Tandem DD404 & DS404


Capacity:

23080 ................ 20 quarts(19 liters)

23105 and26105 ................

28 quarts(26.5 liters)

DD404, front tan-demDD404, rear tan-dem

15.5 quarts(14.5 liters)14 quarts(13 liters)

DS404, front tan-demDS404, rear tan-dem

15.5 quarts(14.5 liters)14 quarts(13 liters)

W4000882

Maintenance 169

Steering Hydraulic System

Fluid type .......... Automatic Trans-mission Fluid(ATF) Dexron® lll

Change interval every 150,000miles (240,000 km)

Hubs

Oil type Temperature

Motor oil APICD or CE, SAE30, 15W40 orsynthetic

Minimum: -15�F(-25�C)Maximum: No limit

Gear oil APIGL5, SAE75W90

Minimum: -40�F(-40�C)Maximum: No limit

170 Literature

Service Assistance and ManualsYour Volvo Truck dealer is trained andequipped to perform expert service on yourVolvo vehicle. Your dealer has direct accessto Volvo Trucks North America, Inc. fortechnical help, parts or service information.

There is also a direct number to Volvo Ac-tion Service (VAS), staffed 24 hours a day,if you are in need of assistance. The num-ber to the Customer Support Center is:1 (800) 528–6586 (or (800) 52–VOLVO).Also on the internet:www.vas.volvo.com

VAS can offer:

DeliveryAssurance

If you have a breakdown,VAS can arrange for loadforwarding or equipmentrental.

PersonalAssurance

Trained staff for handlingany vehicle problems.

UptimeAssurance

VAS will locate the near-est service provider andguarantee payment soyou can get on the roadas soon as possible.

PriceAssurance

VAS audits service andparts billing to ensureguaranteed labor ratesand preferred partspricing for Volvo compo-nents.

There are also five regional offices that cangive information and help. They are locatedin five cities around the US:

Northeast Region - Philadelphia

Ph. (610) 695-6940Fx. (610) 993-2881

Southeast Region - Atlanta

Ph. (770) 751-3120Fx. (770) 751-3149

Midwest Region - Chicago

Ph. (630) 734-4600Fx. (630) 734-3086

Southwest Region - Dallas

Ph. (972) 404-3100Fx. (972) 404-3125

West Region - Salt Lake City

Ph. (801) 352-6301Fx. (801) 352-6350

Literature 171

To order a single Service Manual or a Ser-vice Manual Set for your vehicle, youshould contact your authorized Volvo Truckdealer or fax a request to the Volvo TruckNorth America, Inc. publications warehouse(Fax: (336) 668–3625). They will help youlocate 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 Opera-tor’s Manual).

Prices for a Service Manual Set vary de-pending on what model of vehicle and whatengine it is. Billing will be done throughthe nearest Volvo Truck dealer.

Name Company

Address

CSZ (Province, Postal Code)

Vehicle Model Telephone/Fax

Model Year VIN

Item 1:

Item 2:

Item 3:

Item 4:

Item 5:

172 Service Charts

Scheduled ServicesThe vehicle had a pre-delivery inspection before being delivered to you, the customer.Regular maintenance inspections should be continued. The maintenance program and lu-brication intervals that are listed in this manual may not suit your operation. Contact yournearest Volvo dealer, who can help with designing a maintenance program that works inyour application.

For regular service or maintenance, call the dealer in advance to arrange for a service ap-pointment. This gives the dealer time to schedule the correct equipment and provide atrained technician to service the vehicle. Setting an appointment can decrease vehicledowntime.

When in for service at an authorized dealer, ask for outstanding safety related recalls thatrelate to the vehicle. This service is available only at an authorized dealership.

NOTE! It is strongly recommended thatyou do not attempt to service, repair ormaintain the vehicle yourself unless youare fully trained and have the proper tools,

equipment and parts. Some procedures arebetter performed by your Volvo Truckdealer who has the proper equipment andtrained technicians.

Service Charts 173

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Service Charts 175

Repair Record

Keep track of repairs being made. This helps over the lifetime of the vehicle, to spottrends that can be used to alter maintenance schedules, for example see tables following:

176 Service Charts

Rep

air

Rec

ord

Dat

eM

ileag

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ork

Ord

eror

Invo

ice

No.

Dea

ler

Not

es

Service Charts 177

Rep

air

Rec

ord

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ileag

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ork

Ord

eror

Invo

ice

No.

Dea

ler

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es

178 Service Charts

Rep

air

Rec

ord

Dat

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ileag

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ork

Ord

eror

Invo

ice

No.

Dea

ler

Not

es

Service Charts 179

Rep

air

Rec

ord

Dat

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ileag

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ork

Ord

eror

Invo

ice

No.

Dea

ler

Not

es

180 Service Charts

Rep

air

Rec

ord

Dat

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ileag

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ork

Ord

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Invo

ice

No.

Dea

ler

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es

Service Charts 181

Tire RecordTire 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 life of new or retreadedtires. Dual mounted wheels should always be of the same type and diameter (maximal di-ameter difference allowed is 1/4 in. [6 mm]).

182 Service Charts

Typical Wear Patterns

Incorrect Air PressureA Too high air pressure gives rapid wear

in the middle.

B Too low air pressure gives rapid shoul-der wear.

T1006457

Incorrect CamberIncorrect camber gives abnormal wear onone half of the tire.

T1006458

Incorrect Toe and Axle AlignmentA Incorrect toe-in

B Incorrect toe-out.

C Out-of-line axle

D Steering arm defect

T1006459

Service Charts 183

Dual Wheel MountingA Excessive road camber, different types

of tire, different circumference or off-center loading gives faster wear onone tire.

B Very low air pressure, mismatchedrims for the tire type and dimension,excess flexing in tire wall, or differenttypes of tires in inner and outer tiresgives contact wear.

T1006718

Incorrect Caster and ImbalanceA Caster angle.

B Imbalance.

Also rapidly wears the mechanical parts ofsteering linkage, kingpin and wheel bearing.

T1006460

Cuts in the Tire TreadA Cuts.

B Flaking cuts.

C Rubber flaking.

Cuts are due to poor roads, air pressure toohigh or incorrect tire type.

T1006720

184 Service Charts

Spot WearSudden braking, locking brakes or out-of-round brake drums gives spot wear.

T1006721

Feathered EdgesNormal occurrence on non-driving wheelson good roads and high mileage.

T1006722

CuppingCupping is a normal occurrence that de-pends on the tread pattern; the higher theload, the greater the wear.

T1006723

Service Charts 185

AXLE LOAD/TIRE PRESSURE

Axle Loadlb (kg)

Recommended tire pressurepsi (kPa)

W1000109

186 Service Charts

Tire Record

Size Ply Rating Make Type Serial No.

Service Charts 187

Tire RecordMileageDate

InstalledDate

Removed At Installation At Removal

TireMileage

Notes

188 Service Charts

Tire Record


Service Charts 189


InstalledDate


TireMileage

Notes

190 Service Charts

Tire Record


Service Charts 191


InstalledDate


TireMileage

Notes

192 Service Charts

Fuel and Oil RecordKeeping track of the fuel and oil consumption gives a record of what is normal for the ve-hicle. This can be compared with other vehicles in the same service application to indicatewhat is normal fuel and oil consumption for a certain application.

FilledDate Mileage

Fuel Qty. Oil Qty. SAE No.Notes

Service Charts 193

FilledDate Mileage


194 Service Charts

FilledDate Mileage


Service Charts 195

FilledDate Mileage


196 Service Charts

FilledDate Mileage


Service Charts 197

FilledDate Mileage


198 Service Charts

FilledDate Mileage


Index 199

Index

AAir Dryer Maintenance . . . . 140Air Filter, Sleeper . . . . . . 153Air Filter, VN . . . . . . . . 115Air Filters, Cab . . . . . . . 153Air Tank Draining . . . . . . 140Allison Transmission Oil Capacity165Alternative Fuels . . . . . . . . 62Antifreeze Information, General . 46Antifreeze Standard . . . . . . . 46Antifreeze/Water Mixture . . . . 42

BBattery Maintenance . . . . . 144Brake Maintenance Checks . . 141Brake System Pressure . . . . 143Bulb Replacement List . . . . 145Burn Prevention . . . . . . . . 6

CCanadian Consumer Complaints . 20Climbing Up or Down . . . . . 14Coolant Additive Testing . . . . 49Coolant Additives . . . . . . . 45Coolant Change Interval, Extended 53Coolant Change Interval, Regular 48Coolant Freeze Protection . . . . 47Coolant Mixture . . . . . . . . 42Coolant System . . . . . . . . 38Coolant Water Specification . . . 44Coolant, Changing from Regular toExtended . . . . . . . . . . . 51Cooling System . . . . . . . . 37Cooling System, Draining/Filling,D12 . . . . . . . . . . . . 120Cooling System, Draining/Filling,D7 . . . . . . . . . . . . . 118Crankcase Breather . . . . . . 114Crushing Prevention . . . . . . 13Cutting Prevention . . . . . . . 13

D

DriveShaft Maintenance . . . . 137

EElectric Grounding Practices . . . 17Electric System, Precautions . . . 17Electronic System Precautions . . 18Emissions Control Compliance . . 91Engine Air Filter . . . . . . . 115Engine Compartment Overview 23, 27Engine Damage Prevention . . . 15Engine Data Notes . . . . . . . 34Engine Features . . . . . . . . 29Engine Monitoring Systems . . . 18Engine Oil Change . . . . . . 112Engine Oil Filters . . . . 65, 113Engine Oil, General . . . . . . 63Engine Optional Equipment . 32, 33Engine Overview, D12 . . . . . 25Engine Overview, D7 . . . . . . 21Engine Shut-Down System . . . 18Engine Standard Equipment . 32, 33Engine Storage . . . . . . . . . 35Engine Variants D12 . . . . . . 33Engine Variants, D7 . . . . . . 32Engine, Before Starting . . . . . 16Ether Start . . . . . . . . . 11, 16Explosion Prevention . . . . . . 9

FFan Drive Belts . . . . . . . 116Fire Prevention . . . . . . . . . 9Fuel Additives . . . . . . . . . 59Fuel Cetane Number . . . . . . 57Fuel Cloud Point . . . . . . . . 58Fuel Enhancers . . . . . . . . . 59Fuel Filter . . . . . . . . . . . 56Fuel Filter Change Intervals . . 124Fuel Filter Replacement . . . . 124Fuel Filter Replacement, Primary 125Fuel Filter Replacement, Secondary

127

200 Index

Fuel Pour Point . . . . . . . . 58Fuel Quality . . . . . . . . . . 55Fuel Safety Information . . . . . 54Fuel Storage . . . . . . . . . . 57Fuel Sulfur Content . . . . . . . 56Fuel System . . . . . . . . . . 54Fuel System, Bleeding . . . . 129Fuel Viscosity . . . . . . . . . 58Fuel, Alternative . . . . . . . . 62

GGeneral Coolant Information . . . 41General Engine Design Information21General Information . . . . . . 1

IInjury Prevention . . . . . . . . 6

LLiterature . . . . . . . . . . 170Long-Haul Service Schedule forVN-Series . . . . . . . . . . . 88Lubrication Chart, VN . . . . 157

MMaintenance . . . . . . . . . . 91Maintenance Hazards . . . . . 111Maintenance Safety Precautions . 3Maintenance Service, Long-HaulVN . . . . . . . . . . . . . . 88Maintenance Service, Short-HaulVN . . . . . . . . . . . . . . 78

OOil Additives . . . . . . . . . 72Oil Change Intervals . . . . . . 65Oil Consumption . . . . . . . . 73Oil Pressure Priming . . . . . . 36Oil Quality . . . . . . . . . . 64Oil Sample Examples . . . . . . 75Oil Sample Recommendations . . 77Oil Sample Wear Particles . . . . 76Oil Sampling, General . . . . . 74Oil Sampling, Taking . . . . . . 74Oil Sulfur Level . . . . . . . . 72Oil System . . . . . . . . . . 63

Oil Total Base Number (TBN) . . 72Oil Viscosity . . . . . . . . . . 71Oil, Synthetic . . . . . . . . . 70Owner Information, General . . . 1Owner’s Information Package . . 2

PPower Steering Reservoir . . . 138

RRadiator Package, Cleaning . . 123Rear Axle Oil . . . . . . . . 137Respiratory Hazard Prevention . . 12Roadside Assistance . . . . . 170

SSafety Defects, Reporting . . . . 20Safety Information . . . . . . . 3Safety Information, Brakes . . 139Selling Vehicle . . . . . . . . . 1Service Assistance . . . . . . 170Service Charts . . . . . . . . 172Service Manuals . . . . . . . 171Short-Haul Service Schedule forVN-Series . . . . . . . . . . . 78Spicer Transmission Oil Capacity 165Spring Maintenance . . . . . 150Steering System Maintenance . 138

TTires, Wheels and Hubs Mainte-nance . . . . . . . . . . . . 147Total Base Number (TBN) . . . 72Transmission oil . . . . . . . 135Transmission Oil Quality . . . 136Turbo and Charge-Air-Cooler . 122

VVectro II Parameters . . . . . . 30VECTRO II Parameters . . . . . 31Vendor Component Information . 1Volvo Action Service . . . . . 170Volvo D12 Oil Capacity . . . . 161Volvo Rear Axle Oil Capacity . 166

Vehicle Identification Number (Chassis Number)

Truck Model & Serial

Engine Model & Serial

Transmission Model & Serial

Rear Axle Model & Serial

Your Truck Was Delivered By:

If you need breakdown assistance, contact the VASSupport Center, for towing or repair. VAS is available24 hours per day, 7 days per week at 1-800-528-6586.A Volvo Customer Support Specialist will answer yourquestions or arrange for the assistance you need.

Volvo Action Service (VAS)

Support Center

1-800-52-VOLVO

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

PV776-20 154722 (4,000) 3.2002 © Volvo Trucks North America, Inc. , 2002

Documents

Volvo - Manutenzione e Motore