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Service Manual - Preventive Maintenance

1. W3000818 Preventive Maintenance 53 Check Air Compressor Increase the air pressure until it is 585 kPa 85 psi Time the air pressure build time from that point with the engine at full speed The pressure should reach 690 kPa 100 psi in 25 seconds or less Verify that the governor cutout is at 900 35 kPa 130 5 psi Listen for unusual noises from the compressor while it is running under load and unloaded Check ventilation for dirt and or damage Group 177 W2001414 W2002080 Preventive Maintenance 54 Check Engine Mounting To perform a check of the engine mounting complete the following e Check all brackets bolts and other engine mounting parts for dirt wear and damage 55 Check Radiator Mounting To perform a check of the radiator mounting complete the following e Check all brackets bolts and other radiator mount ing parts for dirt wear and damage 75 Group 177 Preventive Maintenance 56 Check Radiator Fan Bearing Tolerance Bolt Unions Fan Shroud and Fan Ring with Rubber Seal DANGER Ensure that the engine cannot be started while work ing around the fan area Failure to do so may result in serious personal injury or death w2001075 Perform the check of the radiator fan as follows 1 Inspect fan blades for any damage 2 Ensure there is enough clearance between the fan blade tips and the fan ring in the
2. Note With above as the exceptions preset hubs pre mium bearings and seals are warrantied for three years or 563 270 km 350 000 miles by the supplier 26 Group 177 Chassis Springs and Suspension For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Lubricate spring pins using a lithium based grease with EP additives and the consistency of NLG1 No 2 Fill grease until old grease has been pushed out past the seal on both sides and new grease can be seen flowing If grease is not flowing through use a prybar to lever down the spring ends to open up for the grease to flow To perform this procedure the axle must be free hanging Refer to the Service Information in Group 7 Wear tolerance for the spring pin and bushing is 5 mm 3 16 in Design and Function W7000449 27 Group 177 Design and Function T Ride Equalizer Beam For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature In regular over the road operations the T Ride should follow the normal lubrication schedule It is extremely important that the equalizer beam is well lubricated in any off road or on off road ope
3. Check the lift axle air lines for leaks or cracks Check the lift axle springs for wear or damage Check the lift axle for proper operation 95 Group 177 W7000444 W7000759 Leveling Valve W0001880 96 Preventive Maintenance 98 Check Rear Suspension Level Sensors and Leveling Valves To perform a check of the air bellow level sensors and level valves for the air suspension complete the follow ing 1 Check the air spring for wear and cracks Check the level valve for proper operation 2 3 Check the leveling valve for wear and damage 4 Check rod control linkage 99 Check Height Regulation for Air Suspen sion Not applicable for VN VHD vehicles 100 Check Chassis Frame and Crossmembers To perform a check of the chassis frame and crossmem bers complete the following 1 Check the chassis frame for excessive wear or dam age 2 Check the securing fastners for looseness exces sive wear or damage 3 Check the crossmembers for excessive wear or damage Group 177 W5000764 Preventive Maintenance 1 01 Check Central Lubrication System Not applicable for VN VHD vehicles 1 02 Check Compressed Air Lines and Hoses For further information refer to 560 660 Compressed Air Brakes All Models To perform a check of the compressed air lines and hoses complete the following e Ch
4. Move the flange up and down bearing play should not be greater than 1 5 mm 1 16 in Check for oil leaks past the transmission output shaft seal Note There is a difference between sweating and a leak If oil is seeping past the seal after cleaning there is a leak Check driveshaft U joints and slip joint for play There should exist no noticeable play in the U joint bearings The slip joint radial play maximum is 0 18 mm 0 007 in The driveshaft tube should be straight and have no damage or missing weights Remove any build up of foreign material such as undercoating concrete etc Check the torque of driveshaft bolts they should be 170 Nm 125 10 ft lb Check center bearing mounting Check rear axle pinion bearing for wear and leaks past the seal Note The Volvo CT EV87 front tandem gear input shaft has a large play for the input shaft bearing This is nor mal and does not have any damaging effect on the transfer gear during rotation the shaft is balanced so that the clearance is insignificant If there is no oil leak age there is no reason for concern about this play 89 Check Tightness of Rear Axle and Hub Reduction Gear To perform a check of the sealing on the rear axle and hub reduction gear complete the following 1 On the rear axle inspect around the mating sur faces for leaks past the gasket Check brake chamber and air tubing condition Check hub reduction gear for any
5. The Annual inspection is carried out yearly in addition to a Basic inspection This inspection is designed to open up components for inspection or using test equipment to record performance The ideal time to carry out the Annual inspection is right before the hardest season which means just before win ter in the cold weather climates or just before summer in the hot weather climates All inspection points are to be carried out as verification of function or condition Any defects are noted on the in spection form for later correction if so ordered by the vehicle owner Note The standard repair time for performing the Annual Service Preventive Maintenance is based on inspection without repair or adjustment and Oil and Filter Change Group 177 Other Inspection There are additional service points that are carried out at specific mileage or time intervals These are not part of the Preventive Maintenance basic time They should be scheduled as an adjustment or repair job carried out at the same time as the Preventive Maintenance and are listed in this document as reminders only Noise Emissions Volvo Trucks North America Inc warrants to the first person who purchases this vehicle for purposes other than resale and to each subsequent purchaser that this vehicle as manufactured by Volvo Trucks North America Inc was designed built and equipped to conform with all applicable U S EPA Noise Control Regulations at the time
6. out the accumulated moisture frequently and can there fore work with long maintenance intervals Eventually the drying medium fills up and needs replacement Change the cartridge when the medium is filling up more than usual This service rate varies upon the application Dryer manufacturers recommended changing cartridge every two to three years but intervals vary per applica tion The only dryer with regular maintenance is the Midland which requires changing of the coalescent fil ters every year W3000639 W3000628 Group 177 Cab C oo O id CHED CHD W3000881 Preventive Maintenance 1 9 Check Warning and Control Lamps Check all indicators on the instrument cluster Turn the ignition on Wait until the instrument has gone through the start up cycle Press the MODE button until the diag nostic window shows DIAGNOSTICS MENU Press the DOWN button twice and the SET button once The diag nostic window reads BULB TEST Press SET and the internal check program lights up all indicators If any bulb is not functioning note it on the checklist Press the DOWN and SET buttons once and the check program tests the buzzer functions Three different dura tions of the tone are heard Press down the SET buttons again and the check pro gram tests the gauges Most gauges go to half range full range and then back to rest three times Press the DOWN and SET button again for testing the diagnostic di
7. wo N O oO A Inspect battery hold downs for proper placement and tightness Make sure the connections are free from corrosion Inspect cables for proper length chafing and proper routing Check terminals for tightness and cracks Check Specific Gravity of battery acid Check battery fluid level After cleaning spray corrosive preventive on posts terminals and general area around them Ensure that the battery ground connections from the engine to the frame are secure and free from corro sion Note The battery ground connection goes directly to the starter motor 45 Check Fuel Tank Hoses Venting and Mounting To complete a service check of the fuel tank hoses pipes and mountings complete the following 4 2 5 Check the fuel tank mounts Check the fuel tank straps and J brackets and en sure they are tight and that the tanks haven t rotated Inspect the fuel tank brackets for cracks Check the fuel lines for proper routing wear and leaks Check the venting for dirt wear and damage Note Ensure that the fuel lines are not routed too close to the exhaust system Group 177 Preventive Maintenance 46 Check Fuel Tank Ventilation Filter W2001226 To complete a service check of the fuel tank ventilation filter complete the following 1 Inspect the tanks for damage leaks and corrosion 2 Inspect tank vents 69 Group 177 70 W2001
8. 000 miles See specification section for oil types and viscosities ape 80 000 km 50 000 miles nn 96 000 km 60 000 miles an 120 000 km 75 000 miles Volvo Rear Axle Regular oil change intervals for Volvo rear axle is at ev ery 120 000 km 75 000 miles See specification section for oil types and viscosities 115 Group 177 Detroit Diesel Engine Valve Clear ance and Injector Height Check valve clearance and injector height Adjust each as necessary For specific information refer to Detroit Diesel Service Manual Steering System Fluid Change Change steering system hydraulic fluid every 240 000 km 150 000 miles Use Dexron II or Dexron Ill If the fluid is very dark in color there may have been heat problems in the system Note on the inspection form for follow up Cab Fresh Air Filter Change Change cab fresh air filter at 385 000 km 240 000 miles If the vehicle is driven in dusty conditions the fil ter may have to be changed more often 116 ons 190 000 km 120 000 miles Cummins Overhead Set Adjust ment Check valve clearance and injector adjustment Adjust each as necessary For specific information refer to Cummins Service Manual A 240 000 km 150 000 miles en 385 000 km 240 000 miles Feedback One of our objectives is that workshop personnel should have access to correct and a
9. 177 W5000615 W5000609 W7000449 36 Preventive Maintenance Brake Cams For further information concerning brake cams see ser vice information in Group 5 Q Plus LX500 and MX500 Cam Brakes Literature publication number 514 003 and appropriate vendor literature There is one grease fitting on each cam for front and rear wheel brakes Fill with grease until old grease is forced out past the end seal and only uncontaminated grease is visible Note Parking brake should be released so grease can penetrate properly throughout the brake cam Slack Adjusters There is one grease fitting per slack adjuster Fill with grease until old grease is forced out past the splined center and adjustment pawl area and only uncontami nated grease is visible Front Spring Pins There are three grease fittings per spring Fill each fitting with grease until old grease is forced out past both ends of the spring pin and only uncontaminated grease is visi ble Use a pry bar to move spring end up and down until grease comes out of both ends of pin Group 177 W4000771 T4006100 Preventive Maintenance Clutch Bearing and Cross Shaft Volvo clutch is sealed for life and does not need lubrica tion Vendor clutch cross shafts and release bearings need to be lubricated The cross shaft bearings are remotely lu bricated by a hose The grease fitting is located on
10. 62 Check for Exhaust Leakage To perform a check of the exhaust system complete the following 4 2 Check the exhaust flex line for routing Ensure that nothing that is affected by heat is near the exhaust flex line Check for signs of exhaust leaks Check for leaks on the exhaust ports on the cylinder heads at the intake exhaust manifolds and flanges Check for leaks on the exhaust pressure governor and the jointing clamp for the exhaust pipe 79 Group 177 W8001090 W8001283 80 Preventive Maintenance 63 Check A C Compressor Mounting To perform a check of the A C compressor mounting complete the following 1 Check A C compressor mounts for secureness and cracks 2 Inspect the compressor exterior for leaks 64 Check A C Pipes and Hoses To perform a check of the A C hoses fittings switches and wires complete the following 1 Inspect A C hoses and pipes for signs of abrasion wear over heating kinks broken or missing mount ing hardware 2 Look for signs of refrigerant leaks at all connections and hose crimps 3 Check moisture indicator or receiver dryer 4 Check condenser for air flow restrictions Group 177 T2006949 T2012806 Preventive Maintenance 65 Check Air Pipe between Air Intake and Turbo To perform a check of the air pipe between the air intake and turbo complete the following e Check the a
11. Greensboro NC USA Order number PV776 TSP158779 2002 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 me chanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc Contents EEIT a ee I nn eek 3 Preventive Maintenance siseses 3 SBERITICAUENE ae 7 Se a dec E E A E A A A E 7 Iansmissions saesae as 10 Pea 4 gt cn er Pen een Sea RE ie te Meee eter ce eee ee 11 TOONS nee 12 Special Tools and Special Equipment cccsccceeeeceeeeeeeeeeeeeeeees 12 Preventive Maintenance Inspection Bay c cccceseeceeeeeeeeeeeeeeees 19 Design and FUNCION seien bee 21 Valve Aduelnient Internal u een 21 lite zes ee elle lese heat ee ee 21 POS TAKE areas 23 UNNERNAN ein a n 23 Brass ooe S 24 Sor SyS unseren neueren 25 PUDS sasen 26 EE IN A ETEA T E TA TETEE TT E N 27 C minnanna ee 28 Preventive Maintenance 444ss4442444BHennnnnnennnnnnnenennnnnennnnn 29 Annual Service Including Lubrication and Oil Change 29 FIBCODTION ieri ee 33 DUSTRY ieia eee abadamonsanseuces 34 GAR eek ete la ere ns la a tad a a el n el 53 IST EHE anne 63 Engine Compartment Checks une 72 Front Suspension Steering System Checks cccsceeeeeeeeeeeeeeees 83 Checks Beneaih the Ver suisses 86 V
12. Long Life Coolant Note For further information on Fleetgaurd ES Com plete Long Life Coolant refer to the appropriate vendor literature Clutch Hydraulic Fluid Change the hydraulic fluid in the hydraulic system for the clutch The clutch hydraulic system fluid collects moisture from the air and will eventually hold enough moisture to affect the metal surfaces in the system unless removed Drain fluid by removing the lid for the fluid container and then drain through the bleed fitting on the clutch slave cylinder into a container Use bleeder tool 9996928 to refill the hydraulic system with new fluid Use fluid to specification DOT 4 Every Year P very Two Years Caterpillar Coolant Extender Added If using long life coolant in a Caterpillar engine add coolant extender every second year Fan Hubs Check clutch lining condition and thickness every 80 000 km 50 000 miles Use lining wear gauges where applicable Inspect engagement mechanism for air leaks 113 Group 177 Air Dryers The exchange interval of the air dryer cartridge is heavily dependent on how often the compressor cycles off and on and if the climate is hot and moist or cool and dry Caterpillar Engine Valves and In jector Preload Engine valve lash adjustment is checked and if neces sary adjusted every third year Atthe same time adjust the injector preload Refer to the Caterpillar Service Manual for co
13. and Brake Drum Travel To perform a check of the brake lever slack adjuster and brake drum travel complete the following 1 Remove the wheel and brake drums 2 Inspect brake lever for signs of wear or damage 3 Check the connecting clevis pins slack adjusters and brake chambers for wear or damage 4 Verify the following specifications for slack adjuster stroke Relax Stroke Use steel tape to measure from the chamber face to the center push rod eye W5000613 Note 70 mm 2 75 in minimum 73 mm 2 88 in maximum Free Stroke Use a pry bar and steel tape to measure from the chamber face to the center push rod eye Note A B 9mm 37 in Applied Max pressure for the applied Stroke stroke is 586 kPa 85 psi Note Type 16 20 chambers A C 44 mm 1 75 in Type 30 30 chambers A C 51 mm 2 in 5 Check the drum diameters using an inside microme ter The maximum drum diameter is stamped on the drum edge Also refer to any available vendor litera ture for further information 6 Verify that the length of both slack adjusters on an axle is the same 7 Inspect the brake drums for oil cracks heat spots or heavy wear 101 Group 177 102 Preventive Maintenance 1 1 0 Check Load Sensing Valve Not applicable for VN VHD vehicles 1 1 1 Check Brake Chambers and Mounting Brackets To perform a check of the brake chambers and mounting bracket
14. be seen flowing Air Dryers Air dryers have internal maintenance systems that clean out the accumulated moisture frequently and can there fore work with long maintenance intervals Eventually the drying medium will be filled up and the cartridge will need to be changed Change cartridge when there is more water being drained in the daily emptying of the tank than usual This is a progressive development and the time interval will be different from application to ap plication Dryer manufacturers recommend changing cartridge ev ery 2 to 3 years but intervals need to be adjusted for application The only dryer with regular maintenance is the Midland where the coalescent filter needs changing every year Note If a vehicle is operated in a severe weather envi ronment It is recommended to change the air dryer cartridge prior to the severe weather season 24 Design and Function W5000615 W5001194 Group 177 Steering System Steering Linkage and Knuckles For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature For axle forward models grease the steering shaft U joints every 4 months A more frequent maintenance interval may be required if the vehicle is operated under severe driving conditions Design and Function W6000869 25 Group 177
15. it left the control of Volvo Trucks North America Inc This warranty covers this vehicle as designed built and equipped by Volvo Trucks North America Inc and is not limited to any particular part component or system of the vehicle manufactured by Volvo Trucks North Amer ica Inc Defects in design assembly or in any part component or system of the vehicle as manufactured by Volvo Trucks North America Inc which at the time it left the control of Volvo Trucks North America Inc caused noise emissions to exceed Federal standards are covered by this warranty for the life of the vehicle Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below General Noise Shields and Insulation Removing or rendering inoperative the engine and or transmission noise deadening panels shields or insulat ing materials Removing or rendering inoperative the cab tunnel or hood noise insulati
16. the coolant lines for proper routing and that there are no leaks If the oil cooler is air cooled complete the following 1 Check transmission cooler for oil leaks 2 Check that the air flow is free through the core 3 Check all the transmission s pneumatic pipes and hoses for cracks and leaks Group 177 Preventive Maintenance 83 Check Ventilation for Transmission Transfer Case and Power Take Off To complete a check of the ventilation for the transmis sion transfer case and power take off complete the following e Check that the air flow is free through the core for the transmission transfer case and power take off W4002380 8 4 Check Tightness on Retarder and check lines Not applicable for the VN VHD vehicles 85 Check Sound Baffle for Gearbox Not applicable to VN VHD vehicles 89 Group 177 90 W1000035 Preventive Maintenance 86 Check Transfer Case s Mounting Not applicable for the VN VHD vehicles 87 Check Drive Belt for Power Steering Not Applicable for the VN VHD vehicles Group 177 W4000751 W4000754 Preventive Maintenance 88 Check Drive Shaft Universal Joints Slid ing Joints and Support Bearings To perform a check of the driveshaft universal joints slid ing joints and support bearings complete the following 1 Check transmission output shaft bearing for wear
17. 067 Preventive Maintenance 47 Draining of Fuel Tank Dirt Water To complete a service check of the fuel tank ventilation filter complete the following e Drain the fuel tank and check for dirt or water in the fuel system 48 Check Fuel Water Seperator for Fuel Sys tem Draining of Condensation For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature If the filter is not being changed drain the water separa tor Group 177 Preventive Maintenance 49 Check Tire Wear Tire Wear W7000437 Overinflation Abnormal wear in middle Steering Arm Defect Wear only on one tire Underinflation Abnormal shoulder wear Tread Bruises Flaking Cuts Reason Poor roads air pressure too high incorrect type of tires Reason Over energetic braking locking brakes out of round brake drums Rubber Flal 2 Measure tread depth Imbalance or Caster Fault Wear only on non driving wheels 1 Examine each tire tread for unusual wear patterns Refer to chart below for typical tread patterns 3 Check tire pressure and leak test valve stems One Tire Badly Worn Reason Excessive road camber different tire types differ
18. 2189 Airline Release Tool Kent Moore W0001874 J 44773 Airline Release Tool W5001199 J 44966 Wheel Speed Sensor Remover for Heavy Duty Steer Axle and Aluminum Hub Group 177 Tools Cr J 44302 J 44338 A C Schrader Valve Core Removal Tool Oil Dipstick for A C Compressor J 43143 J 22610 J 43143 Drive Shaft Boot Camp Pliers Tie Strap Tensioner J 41610 J 44392 Feeler Gauge Set Fan Belt Tensioner Tool Group 177 Tools PT 5900 9998142 Chip Vacuum Charge Air Cooler Pressure Tester J 38641 B Diesel Fuel Hydrometer Tools Group 177 Other Special Equipment W0001261 J 42397 A Coolant Pressure Test Adapter W7000708 J 38460 A Digital Inclinometer W0001843 3093472 Timken Wheel End Play Gauge Q U 1089953 Bulb Removal Tool J 23600 B Belt Tension Gauge W0001985 J 36795 Tandem Axle Calipers 9996791 Spring Pin Socket Group 177 Tools 9998691 3947553 3949521 3946522 3949523 Oil Filter Nipple Installer Kit Terminal and Shim Kits ll ma HN Joos J 44701 J 44778 J 44779 Battery Tester Kit Driveshaft U Joint and Yoke Kits 16 Group 177 Tools VCADS Pro Tools The following hardware is used to operate VCADS Pro The tools can be ordered from Volvo Trucks North America please refer to the specific tool number when ordering W5001142 C0000285 1 P
19. 5000614 Preventive Maintenance Check ABS System DANGER To do the brake test safely make sure there are no other vehicles within 300 yards when testing or per form the test in a off road area where there is no traffic Performing brake test in traffic may lead to an accident personal injury or death Check the ABS system by attempting to lock up the wheels during hard braking The vehicle should come to a controlled stop Brake from a speed of 50 to 55 km h 30 to 35 mph Make a full brake application Note The rear wheels may lock intermittently while driv ing unloaded under 30 km h 20 mph even when equipped with ABS brakes This is normal in unloaded operation Also check that the ABS telltale indicator comes on and goes out at approximately 8 km h 5 mph 105 Group 177 st o i RPM x 100 W3000815 W2001084 106 Preventive Maintenance Check Engine Controls and Performance Check engine controls and performance while moving through the gears Accelerator pedal should work smoothly and without any hesitation in engine response Engine should accelerate smoothly and without hesita tion misses or surges Also check the exhaust through the mirrors for excessive smoke during acceleration During acceleration in a low gear let engine go to full speed on a flat stretch of road Note maximum engine speed Check the engine manufacturer s specifications for corr
20. C tool package 5 J 43939 9 pin Diagnostic adapter for vehicles built Me te ce j from January 1999 9998555 Communication interface unit 2 l 6 9998496 Pressure gauge 3 9812331 Extension cable 4 an f s 9998495 Air Pressure Hose J 43999 6 pin Diagnostic adapter for vehicles prior to 1999 Group 177 Lighting System Special Tools The tools listed below are used to complete maintenance on the Lighting System for Volvo Trucks They may be obtained from Volvo or where indicated from Kent Moore at 800 328 6657 J 25300 D NN N Te NW J 42395 Rheostat Removal Tool Kent Moore J 43244 Relay Puller Tool Kent Moore 18 Tools Q O 1089953 Lamp Removal Tool Volvo N 20378326 Fuse Puller Tool Volvo Group 177 Tools Preventive Maintenance Inspection Bay Location Preventive maintenance is logically carried out at the same time as lubrication of the vehicle It is then natural to use a bay with a grease pit to be assigned and equipped for preventive maintenance If a pit is not avail able a regular workshop bay can be used with jacks added to the necessary equipment The bay needs to be well lit so inspection can be done without having to use a flashlight unless inspecting in the frame Equipment Inspection bay equipment should be specifically as signed to that bay and not be shared with the rest of the shop The floor equipment should have floor spa
21. Design and Function Steering System For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Use Automatic Transmission Fluid ATF Dexron II or Dexron III for the steering system A darkened fluid indicates a steering system that is run ning hotter than normal and the fluid is overheated Troubleshoot the reason for overheating and change fluid W6000868 Hubs Oil Lubricated Hubs For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Hubs are generally oil lubricated There are no set oil change intervals Change oil when the hub is removed for repairs or other routine maintenance There are conditions that require hub lubrication mainte nance which if not performed can result in shortened bearing life and premature hub replacement e Water ingression e Oil contamination example contaminating synthetic i l W7000438 oil with petroleum based oil e Hub s are run at temperatures above 65 C 150 F e Hub s are run with low oil levels e End play checks are out of specification ranges and hubs have been run too tight or too loose Accept able end play is 001 to 005
22. ER DIR ana 103 EVE PA NS NEERI ETETE RAIN eins canta cian T T AE AE E A ARAE E 113 Additional Time Based Maintenance nnessssessesnneennnnn 113 BEN NEE IE NER IR SEEN cre bee nasties 115 Additional Mileage Based Maintenance ursnsersnnernnennnennnnenen nennen 115 Feedback Group 177 General General Preventive Maintenance Introduction This manual describes inspection and lubrication re quirements during the Annual Service of Volvo vehicles The purpose for performing the preventive maintenance is to ensure that the vehicle is safe and roadworthy over its full lifetime The driver is taking part in the continuous preventive maintenance program by completing the required Daily Pre trip Inspection This is a purely visual inspection that is designed to detect any obvious problems that would make the vehicle unsafe to take on the road Added to the Pre trip Inspection is the Preventive Maintenance Program that is typically carried out by trained personnel using a systematic approach to cover all important com ponents of the new vehicle Preventive maintenance is a planned vehicle mainte nance program that provides an orderly series of servicing and inspecting procedures A well applied maintenance program realizes the investment made in the vehicle The difference between a poorly maintained vehicle and a well maintained vehicle will not show up until later mileages Good maintenance is necessary
23. Preventive Maintenance Hot Check Note The fluid must be hot to insure an accurate check The fluid level rises as the temperature increases 1 Operate the transmission in Drive D range until normal operating temperature is reached e sump temperature 71 93 C 160 200 F e converter out temperature 82 104 C 180 220 F Park the vehicle on a level surface and shift to Neu tral N Apply the parking brake and chock the wheels Allow the engine to idle 500 800 rpm With the engine running remove the dipstick from the tube and wipe clean Insert the dipstick into the tube and remove Check the fluid level reading Repeat the check pro cedure to verify the reading If the fluid level is not within the HOT RUN band add or drain as necessary to bring the fluid level to within the HOT RUN band Group 177 W4000758 W4002393 Preventive Maintenance 6 Check Oil Level in PTO Power Take Off Note For further information refer to Power Take off page 23 Power Take Off Volvo PTO Volvo PTOs mount directly to the transmission and do not need separate oil fill or checks Make sure there is extra oil filled in the transmission for the PTO volume Add with single PTO 0 5 L 0 5 qt with double PTO 0 8 L 0 8 qt Transmission oil heat exchanger should be installed when using PTO continuously over 15 minutes at a time or with a co
24. RVOIR FLUID LEVEL 2 DUMP BODY OIL RESERVOIR LEVEL 34 Q DIFFERENTIAL OIL LEVEL COOLANT LEVEL sy WINDSHIELD WASHER FLUID LEVEL W1000161 Group 177 W6000848 W6000850 W6000869 Preventive Maintenance 1 Chassis Lubrication Note Chassis lubrication should be performed every four months including the annual lubrication Front Axle Steering Knuckles Volvo Two grease fittings on each side one on the top knuckle cover fill with grease until the old grease is forced out past the top seal one on the bottom cover fill with grease until the old grease is forced out past the bottom seal Note Lubrication of the Volvo axle should be done with the wheels on the ground Front Axle Steering Knuckles Meritor and Eaton Raise the axle so the wheels are off the ground before attempting to grease the steering knuckles Two grease fittings on each side one on the top knuckle cover fill with grease until the old grease is forced out past the top seal one on the bottom cover fill with grease until the old grease is forced out past the bottom seal Steering Linkage Steering shaft and draglink are lubed for life Tie rod for Volvo front axles are lubed for life Meritor and Eaton front axle tie rods need to lubricated Fill tie rod end with grease until old grease is forced out past the rubber boot and only uncontaminated grease is visible 35 Group
25. Service Manual Trucks Group 177 501 Preventive Maintenance Annual Service VN VHD PV776 TSP158779 VOLNO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to January 2002 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary ser vice bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a refer ence to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for gen eral information and no reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where personal injury or severe damage to the product could occur Danger Indicates an unsafe practice where serious personal injury or death could oc cur Volvo Trucks North America Inc
26. absorber but only slight resis Upper Shock Mount Bracket tance when collapsing the unit Eyelet Mounting Bolt Chassis Shock Absorber Front Spring Front Axle Beam Lower Shock Mount Bracket Bushing OANOOaARWD 83 Group 177 84 W7000448 Preventive Maintenance 72 Check Steering Knuckle Bearing To perform a check of the steering knuckle bearing complete the following e Check the steering knuckle bearing for excessive dirt wear or damage 73 Check Front Wheel Bearings To perform a check of the front wheel bearing clearance complete the following e Check wheel bearings with a dial indicator Bearing clearance should be within 0 04 to 0 12 mm 0 001 to 0 005 in Group 177 Preventive Maintenance 74 Check Front Wheels To perform a check of the front wheels complete the fol lowing 1 Inspect the hub and tires for excessive dirt wear or damage 2 Check the tire pressure to ensure proper tire infla tion Refer to the appropriate vendor literature for information concerning tire inflation W7001075 Fig 3 Disc Wheel Hub 1 Disc Wheel W7001076 Fig 4 Rim and Spoke Wheel 1 Rim 2 Spoke Wheel 85 Group 177 Preventive Maintenance Checks Beneath the Vehicle 75 Check Tightness Bearing Clearance and Ventilation on the Front Drive Axle To perform a check of the sealing on the front drive axle complet
27. ant is colored red for identifica tion purposes so as not to mistake it for conventional green coolant Long life coolant will test as out of ad ditives SCA but SCA should not be added Fleetgaurd ES Complete Long Life Coolant Note For further information on Fleetgaurd ES Complete Long Life Coolant refer to appropriate vendor literature Fuel The sulfur content in low sulfur fuel has been regulated to a maximum of 0 05 per weight for No 2 D diesel fuel For fuels that have a sulfur content of 0 5 by weight and above most engine manufacturers are re quiring that oil is changed at shorter intervals Sulfur creates highly acidic pollutants in the oil that break down the additives at a higher rate If fuel with a higher sulfur content is used the engine manufacturers recommend that the oil change intervals be reduced Group 177 VOLVO ENGINES Note It is not recommended to mix synthetic oils with petroleum based oils For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Maximum change intervals are 40 000 km 25 000 miles if using oil that meets the Volvo Drain Specification 2 VDS 2 If the oil does not meet the requirements ac cording to VDS change intervals should be 24 000 km 15 000 miles or less Contact Volvo or a Volvo autho rized dea
28. anufacturer or the oil manufacturer has the expertise to analyze driving conditions and to recommend which oil gives the best protection and economy Oil The engine oil lubricates seals cools and cleans the en gine Filtering the intake air and using a low sulfur fuel helps the oil protect the engine parts With better engine designs and improved oils the service intervals have steadily increased The interval choice depends on the engine manufacturer specifications Make sure the cor rect oil type and also the correct viscosity are chosen for the mileage interval driven Periodic oil testing is recommended The test results give a continuous picture of the health of the engine and can warn well in advance of a problem developing The intervals will not cover all applications In on off highway driving severe off highway continuous stop and go city driving and extremely high mileages the oil change interval and preventive maintenance schedule need to be customized for the best protection and econ omy The intervals listed in these specifications are guidelines that should be used in establishing a correct maintenance program Adding unknown additives may put the engine at risk of failure There are many aftermarket oil additives that claim improved performance if added to the en gine oil Each oil type recommended already contains additives that have been tested by a collaboration with engine and oil manufacturers Synt
29. aust is not blocked or leaking Fumes from the exhaust can cause personal injury or death If the vehicle is equipped with a parking heater start the vehicle and run the parking heater for fifteen minutes to perform a function check Note Do not stop the parking heater until it has been al lowed to run fifteen minutes or the function check will be inaccurate Note and correct any faults Group 177 ily a 8 x 10 Is O r 5 RPM x 100 ge m on oun zn of coe W3000815 T0008215 Preventive Maintenance 25 Check Engine Control in Cab Check engine controls and performance while moving through the gears Accelerator pedal should work smoothly and without any hesitation in engine response Engine should accelerate smoothly and without hesita tion misses or surges Also check the exhaust through the mirrors for excessive smoke during acceleration During acceleration in a low gear let engine go to full speed on a flat stretch of road Note maximum engine speed Check the engine manufacturer s specifications for correct speed 26 Check Retarder Control Ensure that the steps of the retarder control are well defined and that the control stops in the set position 57 Group 177 W3000829 W3000881 58 Preventive Maintenance 27 Start Engine and Check of Starter Element and Preheater Starter Motor U
30. avy coat of grease on top of the plate Lubricate Door Locks Hood lock lever front latch is coated with teflon and should not need any conventional lubrication If the mechanism is working hard or binds try cleaning first Clean and lubricate the scissor latch at the base cone receptacle with white lithium grease once per year Steering Gear TRW and Sheppard steering gears may have severe weather seals at input shaft or sector shaft that require greasing Lubricate with a hand grease gun only High pressure grease application may unseat or damage seal Group 177 T1006392 Oil Plug Oil Filter T2012858 Reducing valve Overflow valve for oil filters By pass Oil valve for pistons cooling Overflow valve for oil filters By pass Thermostatic valve Safety valve Preventive Maintenance 3 Change Engine and Oil Filter For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Change engine oil and filters If required by customer take a sample of the oil for analysis Note Make sure the oil type is correct and has the cor rect viscosity The two are not the same and are equally important in giving the right protection for the engine Oil Change DANGER Before working on a vehicle s
31. blems As the vehicle is approached check for signs of leakage general appearance body damage etc Walk around the vehicle Note on the PM inspection form if any leaks or problems are found 33 Group 177 Lubrication Make sure that grease fittings are cleaned off before fill ing grease Dirt on the fitting that is not cleaned off is pushed into the part with the new grease Always fill grease to the point where old grease and contaminants are forced out from the part and only new grease comes out If grease can not be filled so old grease is forced out or if new grease exits without pushing old grease out note this on the form for repair If a fitting does not D407985 NOTE 1 Check clutch reservoir fluid level mounted to bulkhead i ar NO y OX NOTE 2 Generally mounted between frame rails fm GREASE mi a ka Cy IN al gt LA C HEA A PL N a C4 Preventive Maintenance accept lubrication due to damage or internal stoppage replace with a new fitting Do not heat part for better grease application where rub ber or plastic parts are involved Remove excess grease from fittings spring shackles and other surfaces i VOLVO T ride rear suspension has a grease lubricator on the underside of the cradle O ENGINE OIL LEVEL STEERING BOX RESERVOIR FLUID LEVEL Oo TRANSMISSION OIL LEVEL FRONT WHEEL OIL LEVEL CLUTCH RESE
32. ce for storage in between using them and tools should be hung on boards or stored in a cabinet for easy overview and access Install mirrors in four corners of the bay so one person can do a lighting function check without having to leave the cab or rely on a spotter Mirrors do not need to be larger than truck door mirrors Any type of equipment that allows inspection by one person instead of having to use a helper makes inspection easier and faster 20 Group 177 Design and Function Valve Adjustment Interval Check the engine valve clearance after the first six months of operation Check every 12 months thereafter Adjust if necessary For information on valve clearance check and adjust ment refer to Service Information Group 2 Clutch General For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Hydraulic fluid in the clutch system collects moisture from the air and will eventually hold enough moisture to affect the metal surfaces in the system unless removed Replace the fluid at the recommended intervals or more frequently The clutch pedal play 1 is given by the clearance be tween the plunger and the piston 1a in the master cylinder Thus the pedal will always have a play regard less of the clutch adjustment The correct play is adjusted with
33. e Axle _ Check Oil Level in Hydraulic Bogie Lift _ m Check Oil Level in Power Steering wo Check Oil Level in Hubs for Oil Lubricated Wheel Bearings 14 Check Oil Level in Cab Tilt Pump 15 Check Fluid Level in Clutch Fluid Reservoir 16 Check Coolant Freeze Protection and Coolant Level 17 Check Fluid Levels in Windshield Wiper and Headlamp Wiper Reservoirs 18 Check Air Dryer Checks in Cab 19 Check Warning and Control Lamps 20 Check Fault Codes in the Vehicle Electronic Control Unit N Not relevant or applicable Checks in Cab 21 Check Fault Codes in the Engine Electronic Control Unit 22 Check Fault Codes in the ABS Anti Lock Brakes 23 Check Fault Codes in Transmission 24 Function Check of Parking Heater 25 Check Engine Control in Cab 26 Check Retarder Control 27 Start Engine and Check of Starter Element and Preheater 28 Check Pressure Regulator s Disconnection and Connection Pressure 29 Check Air Compressor s Function and Condition 30 Check Sealing on Main Brake Circuit Service 31 Check Parking Brake and Blocking Valve 32 Check Gearshift and Clutch Pedal 33 Check Bogie Lift 34 Check Brake Pedal and Foot Brake Valve 35 Check Hinges Doorstops Locks and Sealing Strips 29 Group 177 External Checks 36 Function Check of Exte
34. e the following e Check the hub for excessive dirt wear or damage e Check the hub for leakage around front driveshaft axle flange e Check the entire axle assembly for wear and dam age 76 Check Clearance in Clutch s Mechanical Function To perform a check of the slack in the mechanical link age for the clutch complete the following e Check shift tower for proper mechanical linkage and function W4000760 77 Check Clutch s Hydraulic and Pneumatic Control System To perform a check of the clutch s hydraulic and pneu matic control system complete the following e Check the clutch s hydraulic and pneumatic system for leaks wear or damage e Check the clutch fluid level 86 Group 177 W4000760 W4000770 T1006766 Preventive Maintenance 78 Check Clutch Wear Start the test drive by checking clutch pedal play and clutch operation Clutch pedal play should be 4 to 10 mm 0 15 to 0 40 in which is the clearance between the pedal plunger and the piston in the master cylinder On vehicles with clutch brake check function by de pressing clutch pedal to within 6 to 12 mm 1 2 to 1 in from the floor while engaging a gear There should be no grating of the engagement teeth when the clutch brake is engaged 79 Check Transmission s Pneumatic and Me chanical Control System To perform a check of the transmission s pneu
35. e wi 108 Check Brake Disc and Brake Calipers MI Check Rear Suspension Level Sensors and Level 109 Check Stroke Length on Slack Adjusters Brake ing Valves Levers and Brake Drums Check Height Regulation for Air Suspension Check Load Sensing Valve Bi 100 Check Chassis Frame and Crossmembers 111 Check Brake Chambers and Mounting Brackets i 101 Check Central Lubrication System r Taom i w rafom CS m 15 ons Dune owa us na ove tert Ding m wfe o 31 Group 177 Preventive Maintenance Note The values seen from cab and backwards are noted in the squares below Brake Linings measured Right thickness in mm in Left Brake Levers Slack Ad Right justers and Brake Drums measured stroke in mm in Left Notes on wear pattern on Right tires OH ide SE le a Cp on Cp CD Co on Left cso co ces Jr gt Ye Vene CI Ce EC Le C T1006800 Comments 32 Group 177 Reception W1000068 Preventive Maintenance When the customer drops off the vehicle the service re ceptionist starts the paperwork and prepares the forms needed for the preventive maintenance Ask the cus tomer about problems that have been noticed while driving the vehicle Ask questions that will make the job easier for the technician to find problem sources Irregular tire wear Unusual noise Unusual vibration Leaks Other operation pro
36. eak detector check the following for leaks Compressor thread connections Compressor crimp connections Compressor shaft seal Condensor tube connections Receiver dryer connections Cab expansion valve Cab evaporator connections Pressure switch connections Schrader valve connections All refrigerant tubing bends and weld joints 3 Recheck for leaks after performing any repair or re placement Group 177 Preventive Maintenance 42 Check Air Intake and Air Deflector Check the air intake grille and air bellows for cracks breaks and broken tabs and clips W8001066 W8001065 43 Check Hood Attachement and Locking De vices Open the hood and check condition of hood restraint cylinders and splash shields Note The restraint cylinders are oil filled and work like shock absorbers W2001069 Check hood lock cables for function and condition Make sure they are not fraying Operate the lock to see if it moves without binding Inspect cab air suspension condition W8000926 67 Group 177 Era W3000859 W2001071 68 Preventive Maintenance 4 4 Check Batteries Dirt Leakage Attach ment Specific Gravity of Battery Acid Fluid Level Connections and Battery Box Note Batteries on U S vehicles are maintenance free To complete a function check of the battery mounting connections and fluid levels complete the following 1
37. eck the compressed air lines and hoses for leaks and cracks e Check the securing fasteners for tightness and wear or damage 97 Group 177 93 Preventive Maintenance 1 03 Check Rear Wheel Bearings Note For further information refer to Service Informa tion Group 7 and Hubs page 26 DANGER Failure to keep wheel bearings properly adjusted can result in accelerated tire wear poor handling and in extreme cases wheel separation from the hub or from the spindle resulting in loss of vehicle control and se rious personal injury or death Note Avoid mixing Synthetic and petroleum lubricants in the same component The wheel hubs are lubricated with several types of oil It is acceptable to use either synthetic or petroleum based oils synthetic oils are not recommended for Volvo Axles Hubs are generally oil lubricated There are no set oil change intervals Change oil when the hub is removed for repairs or other routine maintenance Group 177 Preventive Maintenance 1 0 4 Check Rear Wheels Tire Wear For further information refer to Service Information Group 7 1 Examine each tire tread for unusual wear patterns Refer to chart below for typical tread patterns 2 Measure tread depth W7000437 3 Check tire pressure and leak test valve stems 4 Check the Rim Flange wear on Aluminum Wheels every time the wheel is replaced Note The main caus
38. ect speed Check Engine Brakes DANGER When operating a tractor bobtail without a trailer or on slippery roads the engine brake switch must be in the OFF position Failure to follow these instructions can result in loss of vehicle control and serious personal injury or death If the engine is equipped with an exhaust brake Volvo only or an engine brake VEB check the effectiveness of the retarding force when the brake is engaged Engine Brake VEB The engine brake has two operation modes high and low that are selected by one or two switches on the dashboard Make sure the brake function disengages by e Either depressing accelerator or clutch pedal e Engine speed goes under 1 000 rpm e Vehicle speed goes under 2 mph 3 km h Turbo boost pressure going over 150 kPa 22 psi e Engaging PTO Engaging ABS Group 177 W4000724 W3000807 W6000828 W1000065 Preventive Maintenance Check Transmission Operation Check the transmission for smooth operation through the gear pattern Listen for any unusual noise during shifting Check for excessive play in the shift lever Drive vehicle in all gears and listen for any unusual dif ferences in sound between the gears Check Cruise Control If equipped engage cruise control It should engage and disengage smoothly Make sure the engine does not surge when in cruise control mode Check the re
39. ent diameters unsuitable loading Contact Wear Reason Insufficient air pressure wrongly matched rims for tire type and size excess in tire body and different tire types in inner and 22 000 Ibs outer tire EN Check the 4 200 Ibs 5 500 Ibs 6 820 Ibs 5 280 Ibs diameter Toe and heel wear is a normal occurrence depending on tread pattern Compression and extension The GREATER the load the GREATER the wear W1000062 71 Group 177 Engine Compartment Checks fl bop a 4 W3000978 W3000978 72 Preventive Maintenance 50 Check Alternator Mounting Check the alternator mounting for wear or damage 51 Check Electrical Connections and Cables for Alternator Starter Motor and Preheater e Check the electrical connections for the alternator starter motor preheater for dirt corrosion and dam age Group 177 W2003743 1 Tensioner against the install stop or free arm stop W2003742 2 Metal to metal contact between the arm and springcase Preventive Maintenance 52 Check Drive Belts DANGER Ensure that the engine cannot be started while work ing around the fan area Failure to do so may result in serious personal injury or death For further information refer to Function Group 2 and ap propriate vendor literature To perform a function check of the drive belts complete the following 1 Using a belt tensio
40. es of tire wear are faulty air pres sure incorrect toe adjustment and incorrect drive tire alignment or thrust angles which can cause pushing or scrubbing of the steer tires Feathered edges of the tires is an early symptom of tire wear 1 0 5 Check Differential Locks To perform a check of the differential locks complete the following 1 Check the differential locks for wear or damage 2 Check that the differential locks are operational 11006487 99 Group 177 __W5000610 W5000604 W5001317 100 Preventive Maintenance 1 06 Check Brake Linings To perform a check of the brake linings complete the fol lowing e Measure the brake lining through the inspection holes in the backing plates See manufacturer s specifications for minimum lining thickness 1 07 Check Brake Cylinders Levers and Forks To perform a check of the brake cylinders levers and forks complete the following 1 Remove the wheel and brake drums 2 Inspect the brake cylinders levers and forks for signs of wear warp or cracks 1 08 Check Brake Disc and Calipers Note Not applicable for VN vehicles To perform a check of the brake discs and calipers com plete the following 1 Remove the wheel 2 Inspect the brake discs and calipers for signs of wear or damage Group 177 Preventive Maintenance 1 09 Check Stroke Length on Slack Adjusters Brake Levers
41. et the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Take precautions when draining the oil Wear gloves and let the engine cool down before draining Serious burns can result from contact with a hot engine or hot engine oil Use rubber gloves when handling used oil Wash skin thoroughly if it comes in contact with used oil Pro longed contact with used engine oil may be harmful It is important to drain as much oil as possible Try to change oil immediately after driving when the oil is warm Always replace the oil filters when changing oil Note Always dispose of oil according to Federal and lo cal regulations Used oil disposed of inappropriately can contaminate nature waterways community drinking wa ter and kills wildlife 39 Group 177 W2003480 W2003078 D7 Oil Filters 1 Full flow Filter 2 Bypass Filter 40 Preventive Maintenance Oil Filters Use only the engine manufacturer s oil filter for re placement Use of an oil filter not built to specification could result in severe damage to bearings crankshaft etc as a result of unfiltered oil entering the lubrication system Note Always dispose of oil according to Federal and lo cal regulations Used oil disposed of inappropriately can contaminate nature waterways community drinking wa ter and kills w
42. etroit Diesel Publications for details More frequent oil changes are also required if the engine is operating in a dusty environment or if frequent stops and starts are made Oil filters should always be changed when changing oil Supplemental coolant additives are recommended for all Detroit Diesel cooling systems Antifreeze alone does not provide sufficient corrosion protection for heavy duty diesel engines Note The Detroit Diesel Engine is installed in earlier VN vehicles from 1996 2001 only CATERPILLAR ENGINES For further information refer to the appropriate vendor literature Caterpillar does NOT recommend an automatic exten sion of oil drain intervals with high quality oil low sulfur fuel and non severe duty driving Oil drain intervals can only be extended with an oil analysis program containing the following elements oil condition and wear metals trend analysis fuel consumption and oil consumption In areas where fuel sulfur content exceeds 1 5 choose an oil with a total base number that is within the API CF 4 or CG 4 categories and shorten the oil change pe riod based on oil analysis Shorter oil change intervals are required if the engine is operating in a dusty environment or if frequent stops and starts are made see oil change interval below Oil filters should always be changed when changing oil Supplemental coolant additives are recommended for all Caterpillar cooling systems Antifreeze alone d
43. f 420 kPa 60 psi 29 Check Air Compressor s Function and Condition Raise the air pressure until it is 585 kPa 85 psi Time the air pressure build time from that point with the en gine at full speed The pressure should reach 690 kPa 100 psi in 25 seconds or less Verify that the governor cutout is at 900 35 kPa 130 5 psi Listen for unusual noises from the compressor while it is running under load and unloaded When the governor cuts out check for air dryer exhaust function by listening for the air release from the air dryer through the door or window 30 Check Sealing on Main Brake Circuit Ser vice To perform the check of the Main Brake Seal perform the following 1 Start engine 2 Charge the Compressed Air System to 750 kPa 7 5 bar 3 Shut off engine 4 Release the parking brake 5 Apply the foot pedal for a minimum of five minutes Use a pedal jack whenever appropriate 6 Check the Dual Pressure Gauge and ensure that the pressure drop doesn t exceed 10 kPa 1 57 psi 7 Listen for air leaks 8 Disconnect the Dual Pressure Gauge from the com pressed air tank 59 Group 177 W5000599 W8001384 60 Preventive Maintenance 31 Check Parking Brake and Blocking Valve Check the parking brake and blocking valve holding power by engaging direct gear not allowing the engine speed to go above 1000 rpm and attempt to drive off with the
44. hen draining the oil Wear gloves and let the engine cool down before draining Serious burns can result from contact with a hot engine or hot engine oil Check the oil level through the top plug The oil should be level with the hole Add oil if necessary Drain oil through the bottom plug Drain oil immediately after driving the vehicle so that the oil is hot Note Also check the rear axle ventilation for blockage Blockage can cause extreme pressure in the axle and create leaks Hub Reduction For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature If the axle is equipped with hub reduction empty each hub separately when changing oil Turn the wheel until the drain plug is at it s lowest position Remove plug and drain Fill oil through the level fill plug hole Fill each hub reduc tion before filling oil in the rear axle Note Synthetic oil is not recommended for the Volvo transmissions 47 Group 177 T0008128 1 Level Fill Plug 2 Drain Plug 70008164 1 Level Fill Plug 2 Drain Plug Improper Oil Level Proper Oil Level W4000768 48 Preventive Maintenance 1 0 Check Oil Level in Rear Drive Axle Note For further information refer to Rear Axle page 11 Checking and Draining Oil Wear protecti
45. her information on Noise Emis sions refer to Noise Emissions page 5 Perform the check of the radiator hoses and pipes as follows 1 Check the front area of the radiator package for dirt and debris that hinders air flow 2 Clean the radiator package with compressed air or water pressure blowing or pushing from the inside out Note Air pressure should not exceed 200 kPa 30 psi for the radiator and charge air cooler cores Note If there is damage to the cooling fins straighten them out so air can flow freely 3 Check for fluid leaks on or around the engine Note Inspect the mating surfaces auxiliary compo nent attaching areas and hook ups hoses and pipes 4 Pump up pressure in the relief valve with the heater controls open to 75 kPa 11 psi Leave under pres sure for five to ten minutes Look for leaks wear cracking and distortion on hoses and tubing 5 Check the hose clamps for tightness 77 Group 177 T2015533 W4002380 78 Preventive Maintenance 59 Check Intercooler Pipes Hoses and Air Flow Note This check is also considered Noise Emissions Control Maintenance which is required maintenance for any Volvo vehicle For further information on Noise Emis sions refer to Noise Emissions page 5 Always wear appropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids To perform a check of the intercooler pipes and ho
46. hetic oil is offered as an alternative to the traditional petroleum based oil for the engines The ability of syn thetic oil to protect the engine is better than regular oil but its life is the same as for regular oil This is because of the combustion by products that contaminate the oil These contaminates will make the change intervals the same as for regular oil However in extreme driving con ditions a synthetic oil may be the only choice for the application Note It is not recommended to mix synthetic oils with petroleum based oils Coolant The engine coolant protects the cooling system from freezing or boil over problems It also protects against corrosion and cylinder liner pitting Coolant requirements are based on the additive levels present in the cooling system To be able to run the cooling system as long as 2 years between coolant changes there must be a re plenishment of additives as they are used up Testing should be done regularly to be sure the additive levels are within recommended levels Never run the engine with only water in the cooling system Always use a mixture of clean water and a rec ommended antifreeze The mixture should never be less than 40 antifreeze and 60 clean water or more than 60 antifreeze and 40 clean water Texaco Extended Life Coolant Note For further information on long life coolant refer to Service Bulletin 260 002 Texaco Extended Life Coolant Texaco Long life cool
47. ildlife Install new filters as follows e Coat the filter gasket with oil e Install the filter and turn it by hand until the gasket makes contact with the sealing surface e Then turn the filter an additional 3 4 turn Oil Level Check Note Do not let the oil level drop below the lower mark ing on the dipstick Do not overfill so the level is above the upper marking on the dipstick Wait five minutes after shutting off the engine before checking the oil level This gives the oil time to drain back to the oil pan Group 177 Improper Oil Level Proper Oil Level W4000768 Preventive Maintenance 4 Check Oil Level In Manual Transmission For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Note Synthetic oil is not recommended for the Volvo transmissions Volvo Perform the first oil and filter change at 10 000 km 6 000 miles See specifications for regular oil and filter change intervals Ensure that the filter cover is secure after changing the filter Fuller Petroleum based oil Perform the first oil and filter change at 5 000 to 8 000 km 3 000 to 5 000 miles See specifications for regular oil and filter change intervals Synthetic lubricant No initial oil change is neces sary See specifications for the regular
48. information display e Instrument e Vehicle ECU e Engine ECU e ABS Control Unit e EBS Control Unit e Air Suspension Control Unit e Retarder Control Unit e Load Indicator Control Unit e Air Bag Control Unit e Anti Theft Control Unit Ensure the engine is switched off during the service check and the starter key is in the drive position I The control lever on the right hand side of the wheel is used to communicate and read off any fault codes on the instrument s driver information display 1 Read any fault codes by using the control lever and display These fault codes are saved in the vehicle s control units 2 Write down and fault codes displayed and then cor rect the faults 3 After correction zero out the fault codes Fault codes can be read also with a diagnosis output PC This instrument is placed underneath the instrument panel on the driver s side of the vehicle Group 177 Engine ECU NOT POD W5001348 Toothed Hub or Tooth Wheel Sensor ECU ABS Valve Relay Valve TCS Valve J1922 J1939 Connector 72006602 Preventive Maintenance 21 Check for Fault Codes in the Engine Elec tronic Control Unit Use Service Information in Function Group 23 as a refer ence When reading fault codes perform the following e The engine is off e The parking brake is applied e The starter key is in the drive
49. ing release operate release mechanism while listening through door or have a helper check the function Verify that the telltale indicator on the instrument cluster lights up Note If vehicle air pressure is below approximately 720 kPa 75 psi pneumatic switches will not function This is a safety lockout for the air brake system Operate the differential lock switch es Verify engage ment by listening to the lock mechanism operating and that the telltale indicator lights up on the instrument clus ter If equipped with air suspension levelling switch operate the switch Verify function by watching the chassis being lowered Verify that the telltale indicator lights up on the instrument cluster Make sure the lock function of each switch works so that the switch can not be engaged without operating the lock Check Steering Column Adjustment Press down the release pedal and move the steering wheel column through its possible positions It should be possible to move the steering column without binding or using excessive force When the pedal is released the column should be firmly locked in place Check Horns Sound both the air horn 1 and the electrical horn 2 Each should have a strong even tone 109 Group 177 y rr io 5 a W3000815 W3000819 W5000612 110 Preventive Maintenance Engine Low Idle Record the engine low idle speed Liste
50. ir pipe etween the air intake and turbo for wear damage and cracks 66 Check Turbocharger and Regulator DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment To complete a check of the turbocharger and regulator complete the following 1 Check the turbocharger attached oil pipes clamps nuts and airlines for wear damage dirt and cracks 2 Check the regulator for wear damage dirt and cracks 81 Group 177 Preventive Maintenance 67 Check Pump Coupling for Injection Pump Electronic Engines Not Applicable CY O QJ Sor e oO z To perform a check of the pump coupling for the injection OE s a pump complete the following e9 e Check the pump coupling is in good condition and clean There must be no traces of oil or other impu rities 68 Check Tightness on Servo Pump Oil Lines and Steering Gear To perform a check of the tightness on the servo pump oil lines and steering gear complete the following e Check that the servo pump is secured tightly to
51. kage by observing the air pressure gauges for pressure decrease Maxi mum leak permitted over one minute is 10 kPa 1 5 psi 61 Group 177 62 W8000890 Preventive Maintenance 35 Check Hinges Doorstops Locks and Seal ing Strips Check the following door functions and verify their opera tion Check that the door hangs properly on the hinges and that the lock functions properly Check that doorstops and sealing strips are in work ing condition free from damage and improper wear Group 177 Preventive Maintenance External Checks 36 Function Check of External Lamps To perform a function check of the external lamps per form the following 1 Check all external lighting for operation 2 Check that all lamps are in good condition W3004425 37 Check Rear View Mirrors and Reflectors To perform a function check of the mirrors and reflectors complete the following 1 Check that the rear view mirrors are in good work F ing condition and remain in position when set 2 Check the attachments for the rear view mirrors and ensure they are functional 3 Check the reflectors for functionality and that none are missing W8001420 63 Group 177 Preventive Maintenance 38 Function Check of Wipers and Washers Check the wiper arm tension and condition of the wiper blades W3000786 39 Check Headlamp
52. leaks or cracked sealant 91 Group 177 W4000752 W4000754 92 Preventive Maintenance 90 Check Bearing Clearance in Pinion and Rear Axle Input Shaft To perform a check of the bearing clearance in the pin ion and rear axle complete the following 1 Use a dial indicator to check bearing clearance in the pinion and rear axles The clearance should be within 0 04 to 0 12 mm 0 001 to 0 005 in 91 Check Rear Drive Axle Ventilation To perform a check of the rear drive axle ventilation complete the following e Check the rear drive axle for proper ventilation it should also be free from excessive dirt wear or damage Group 177 W6000827 Preventive Maintenance 92 Check Exhaust Pipe and Silencer Note This check is also considered Noise Emissions Control Maintenance which is required maintenance for any Volvo vehicle For further information on Noise Emis sions refer to Noise Emissions page 5 To perform a check of the exhaust pipe silencer or par ticulater complete the following e Check if there is exhaust leakage around the ex haust ports on the cylinder heads at the intake and exhaust manifolds and at the flanges exhaust pipe s and silencer e Check if there is exhaust leakage at the jointing clamp for the front exhaust pipe 93 Check Rear Springs and U Bolts To perform a check of the springs and U bolts co
53. ler to obtain a list of approved VDS oils Shorter oil change intervals maybe required if the engine is operating in a dusty environment or if frequent stops and starts are made Supplemental coolant additives are recommended for all Volvo cooling systems Antifreeze alone does not provide sufficient corrosion protection for heavy duty diesel en gines If the fuel has a sulfur content exceeding 0 5 by weight halve the indicated maximum mileage intervals Oil filters should always be changed when changing oil CUMMINS ENGINES For further information refer to the appropriate vendor literature If the engine is operating in ambient temperatures con sistently below 20 C 0 F or above 40 C 100 F perform maintenance at shorter intervals Shorter inter vals are also required if the engine is operating in a dusty environment or if frequent stops and starts are made Oil filters should always be changed when changing oil Supplemental coolant additives are recommended for all Cummins cooling systems Antifreeze alone does not provide sufficient corrosion protection for heavy duty diesel engines Maximum Oil Drain Intervals Note Extended oil drain intervals are not recommended Specifications Group 177 DETROIT DIESEL ENGINES For further information refer to the appropriate vendor literature The use of fuels with a sulfur content above 0 5 by weight will require more frequent oil changes Refer to D
54. llow knob pops out This should happen at a pressure of 170 35 kPa 25 5 psi Now try to push in both knobs They should not stay in on their own Group 177 W3000818 u W3000755 Preventive Maintenance Check Compressor Loading Raise the air pressure until it is 585 kPa 85 psi Time the air pressure build time from that point with the en gine at full speed The pressure should reach 690 kPa 100 psi in 25 seconds or less Verify that the governor cutin is at 758 68 kPa 110 10 psi and cutout is at 900 35 kPa 130 5 psi Listen for unusual noises from the compressor while it is running under load and unloaded When the governor cuts out check for air dryer exhaust function by listening for the air release from the air dryer through the door or window Check Wipers and Washer Check the windshield wipers and washer from inside the cab Wipers should operate smoothly and without any binding in the sweep Listen for any unusual noise The blades should clear the swept area without leaving streaks or missing any spots Check the intermittent mode function Note To shorten the interval time move the lever to nor mal wipe position and then to the interval wipe position again when the next wiper sweep is desired This way the interval can be programmed between 1 10 sec onds Operate the windshield washer and check that the spray pattern covers the wind shield effectivel
55. ls are followed as limits Maintenance can be done before either 24 000 km 15 000 miles have been reached or before 4 months are up but must be made at or before either the mileage or the time limit has been reached Advantages A well planned preventive maintenance program offers the following advantages The lowest attainable maintenance cost Maximum vehicle uptime Better fuel economy Reduced road failures greater dependability Increased customer confidence better public rela tions Less possibility of accidents due to defective equip ment Fewer driver complaints Regardless of the planning and the details of the mainte nance program the success of the program hinges on the caliber of workmanship in performing the actual inspection A major cause of failure is a pencil inspec tion that is the mechanic checks off each operation as being OK without making the actual inspection A pencil inspection defeats the purpose of the inspection which is to detect an impending failure Maintenance Form A service manual is issued detailing the current inspec tion forms Forms are created for different users but all with the same references to this document When the in spection point is carried out check the box if the item is OK If further work such as adjustment repair etc needs to be performed check that box and go on with the next inspection point Items noted as being faulty or in need of adju
56. matic and mechanical control system complete the following 1 Check the top of the transmission 2 Inspect lower shift boot condition 3 Inspect the top covers for leakage and the shift lever for leakage and wear 80 Check Seals for Speedometer Sensor and Joint Coupling To perform a check of the seals for the speedometer sensor and joint coupling complete the following 1 Check the speedometer sensor seals for wear cracks or any other damage 2 Check the joint coupling for secureness and wear or damage 87 Group 177 W4002380 W4000769 Oil Cooler W4002536 Oil Water Cooler 88 Preventive Maintenance 81 Check Tightness on Transmission Trans fer Case and Power Take off including check of lines To perform a check of the tightness of the transmission transfer case and power take off complete following e Visually check the transmission for secureness and any worn or broken clamps bolts or other securing devices e Visually check the transfer case for secureness and any worn or broken clamps bolts or other securing devices e Visually check the PTO for secureness and any worn or broken clamps bolts or other securing devices e Check all lines and hoses for leaks 82 Check Tightness on Cooler for Transmis sion To perform a check of the tightness of the oil cooler for the transmission complete following e On the oil cooler check
57. mplete the following 1 Check the springs for damaged or broken leaves 2 Check the spring bushing location in the spring eye 3 Inspect the U bolts for signs of movement or wear 4 Check that the spring center is aligned with the cen ter of the spring pad on the front axle beam Verify this alignment by inspecting the underside of the spring to see if there are any signs of movement be tween the spring and the axle member 94 Check Anti Roll Bar Not applicable to VN VHD vehicles 93 Group 177 Preventive Maintenance 95 Check Rear Shock Absorbers For further information refer to 761 002 Shock Ab sorbers Front and Rear To perform a check of the rear shock absorbers com plete the following e Check the rear shock absorbers for excessive dirt wear or damage W6000836 96 Check Mounting for Front and Rear Axle To perform a check of the mounting for the front and rear axles complete the following 1 Check the mounting for the front axle for tightness w7000763 and excessive wear and damage 2 Check the mounting for the rear axle for tightness and excessive wear and damage 94 Group 177 Han Sy iy W5001185 Preventive Maintenance 97 Check Bogie Lift or Lift Axle To perform a check of the bogie lift or lift axle complete the following 1 2 3 4 Check the lift axle for excessive wear and damage
58. n for idling prob lems such as surging missing or unusual noise See each engine manufacturer s specification for correct idle speed Record low and high oil pressure Check Low Air Warning Switches Pump the brake pedal while observing the air gauges As the air pressure is lowering verify the compressor governor cut in pressure and the low air warning switches cut in pressure Check that both indicator lights in the lower right corner and the Master Warning indica tor lights up and make sure the buzzer sounds Governor cut in should be at 790 35 kPa 115 5 psi The low air warning switches should close at a minimum pressure of 420 kPa 60 psi Check Manifold Dash Valve Start the manifold dash valve check by pulling out the yellow knob Parking At the same time the red knob Trailer Air Supply should also pop out Press both knobs in Note The gauges should only be used for general refer ence Gauges are less accurate below 275 kPa 40 psi Lower the air pressure by pumping the foot brake valve to the point where the red knob pops out Verify that this happens at a pressure of 275 35 kPa 40 5 psi Hold the red knob in manually and decrease the pres sure further At a pressure of 210 35 kPa 30 5 psi a tripper valve starts to exhaust the air supply to the trailer This is the non override function working Release the red knob Continue to decrease air pressure until the ye
59. n meter check fan belts for cor rect tension Note For manual tensioning systems only 2 Inspect the belts for wear cracks and fraying 3 Check along the belts for proper alignment 4 Visually inspect hubs and pulleys for wear and dam age 5 Inspect the vibration damper for leaks or any sur face damage 6 With belt on the drive e Check if the tensioner is against the install stop or free arm stop Replace the belt if this condi tion is seen e Check if the belt is tracking all the way to one edge of the tensioner pulley A witness mark considerably wider than the belt may be seen on the pulley under this condition and the ten sioner should be replaced 7 Remove the belt by pulling the tensioner back with a breaker bar Slowly return the tensioner to its free arm stop Perform the following e With the breaker bar slowly pull the tensioner back from the free arm stop to the install stop and slowly release again If the tensioner ex hibits excessive roughness or hesitancy during this cycle replace the tensioner e Check for metal to metal contact between the arm and springcase Replace if metal to metal contact is seen e Check to see if there are any cracks in the ten sioner or if the stops on the springcase are broken Replace the tensioner if either of these conditions is seen 8 Reinstall the belt ensuring that the belt is properly seated in the grooves of all pulleys 73 Group 177 74
60. ng materials Removing or rendering inoperative any truck body mounted sound insulation components and or shields e g cab or fender shields skirts wheel housing splash shields etc Engine Control and Fuel Systems Removing or rendering inoperative or modifying the en gine control system such a 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 engine speed limits Cooling System Removing or rendering inoperative cooling system com ponents e g temperature controlled fan clutch fan shroud fan ring recirculation shields etc Exhaust System Removing or rendering inoperative exhaust system com ponents e g muffler pipes clamps etc Air Intake System Removing or rendering inoperative air intake induction system components e g filter filter housing ducts etc Group 177 Safety Advice DANGER Never operate a diesel engine in an area where hy drocarbon vapors gasoline for example are present or are suspected to be present Hydrocarbon vapors can enter the air intake and make the engine over speed causing severe damage and or explosion or fire Serious personal injury or death can occur DANGER When entering and exiting the cab use caution Al ways have a firm hand hold and or stable foot position before transferring weight to that position Do not carry anything
61. ntinuous power output over 55 C W O 75 hp Without heat exchanger the oil can overheat and cause damage to the transmission If the application has a pump that is installed separately or a blower with a driveshaft connection the driveshaft U joints need to be greased at every maintenance inter val or more often depending on usage Use a lithium based grease with EP additives and of the con sistency of NLGI No 2 Side Engine Mounted PTO During operation the pump must always be filled with oil Otherwise damage to the pump will result Engine mounted PTOs mount directly to the engine and need to be checked before vehicle operation Make sure the hydraulic system is filled above the low limit mark of the hydraulic reservoir 45 Group 177 46 Level Fill Plug Drain Plug T1006646 Preventive Maintenance 7 Check Oil Level in Retarder To ensure the correct oil level in the retarder the oil level should be checked when the retarder is warm 8 Check Oil Level in Transfer Case Not applicable for VN VHD vehicles Group 177 T0008128 1 Level Fill Plug 2 Drain Plug 70008164 1 Level Fill Plug 2 Drain Plug Improper Oil Level Proper Oil Level W4000768 Preventive Maintenance 9 Check Oil Level in Front Drive Axle Note For further information refer to Driveshaft page 23 Checking and Draining Oil Take precautions w
62. oes not provide sufficient corrosion protection for heavy duty diesel engines Note Caterpillar Engines were installed in earlier VN ve hicles from 1996 1999 only Specifications Group 177 Specifications Transmissions Includes Volvo Eaton Fuller Meritor and Allison HD Transmissions For further information concerning component specifications see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Group 177 Specifications Rear Axle Includes Volvo Arvin Meritor and Eaton Dana Rear Axles For further information concerning component specifications see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Group 177 Tools Tools Special Tools and Special Equipment The following special tools are recommended for use in the preventive maintenance in spection Special tools can be ordered through the Volvo Special Tools program in the parts ordering system or directly from Kent Moore by calling 800 328 6657 Kent Moore tool numbers are preceded by a J Please refer the specific tool number when ordering Special Tools W0001489 J 42942 ABS Sensor Adjustment Tool Kent Moore W0001731 J 44399 Air System Tester W0001896 J 44769 Wheel Speed Sensor Extractor 12 Is f W0001198 J 4
63. oil and filter change intervals Meritor Petroleum based oil Perform the first oil and filter change at 5 000 to 8 000 km 3 000 to 5 000 miles See specifications for regular oil and filter change intervals Synthetic lubricant No initial oil change is neces sary See specifications for the regular oil and filter change intervals 41 Group 177 42 W4002517 Preventive Maintenance 5 Check Oil Level in Automatic Transmission Note For further information refer to Transmissions page 10 Transmission fluid cools lubricates and transmits hy draulic power Always maintain proper fluid level If fluid level is too low the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats If the level is too high the fluid aerates caus ing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high Transmission fluid check 1 Clean all dirt from around the end of the fluid fill tube before removing the dipstick Do not allow dirt or foreign matter to enter the transmission Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages Check the fluid level using the following procedure and record the level in your maintenance log 2 Always check the fluid level reading with the engine running at least t
64. p 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature The power steering fluid reservoir contains Automatic Transmission Fluid ATF Dexron Ill If the fluid has darkened then that indicates that the power steering system is running hotter than normal and overheating the fluid Report the problem to and service W6001428 the vehicle at a Volvo Truck Dealer 49 Group 177 Preventive Maintenance 1 3 Check Oil Level in Hubs for Oil Lubricated Wheel Bearings Note For further information refer to Hubs page 26 Front Wheel Hubs DANGER Failure to keep wheel bearings properly adjusted can result in accelerated tire wear poor handling and in extreme cases wheel separation from the hub or from the spindle resulting in loss of vehicle control and se rious personal injury or death W7000438 The front wheel hubs are lubricated with several types of oil The suggested types are SAE 30 or 15W40 It is ac ceptable to use either synthetic or petroleum based oils Synthetic oils are not recommended for Volvo Axles Axle oils API GL 5 and SAE 75W 90 are acceptable as well Hubs are generally oil lubricated There are no set oil change intervals Change oil when the hub is removed for repairs or other routine maintenance Check Oil Level in Cab Tilt Pump MT 14 ee This option not available on VN VHD vehicle
65. parking brake still applied The parking brake should hold the vehicle stationary while letting the clutch up slowly Release the parking brake and start driving Check that the parking brakes are released quickly and that no braked drag can be felt 32 Check Gear Shift and Clutch Pedal To perform a service check on the Gear Shift and Clutch Pedal complete the following 1 Move the gearshift to range and split gear positions Listen to the sound when passing through neutral and checking the range gear The control lamp should light up when the high split gear is engaged 2 Check on the automatic gearbox that the engine can only be started when the gear selector is in neutral N 3 Check that there is no excessive play in the gearshift 4 Check that the gear stick gaiter fits tightly and is not cracked Group 177 W3000810 W5000607 Preventive Maintenance 33 Check Bogie Lift Check the bogie lift by pressing the air suspension level ling switch Verify function by watching the chassis being lowered Verify that the telltale indicator lights up on the instrument cluster 3 4 Check Brake Pedal and Foot Brake Valve Letting the engine run at low idle depress the brake pedal to full brake pressure depress pedal only once so the compressor does not start loading again Let the brake pressure stabilize Hold pressure steady for one minute and check that there is no lea
66. position I 1 Read on the display that no fault codes are saved in the EECU 2 Press the diagnosis button for four seconds 3 CHECK ENGINE lamp shines steadily for three seconds after the starter key is turned to the drive position l 4 Write down any fault codes Fault codes can be read via diagnosis output using a PC 22 Check for Fault Codes in the ABS Anti Lock brakes Note Use Service Information in Function Group 59 as a reference To complete the Fault Code Check for ABS perform the following 1 Check that no fault codes are saved in the ABS ECU 2 Write down any fault codes require correction Note Fault codes can also be traced using a diagnostic program run through a PC 55 Group 177 W8001006 1 Utility Outlet 2 Option Switches 3 Clock 4 Alarm Switch 5 Fan Control 6 Temperature Control 7 Lighter 56 W4002407 Preventive Maintenance 23 Check for Fault Codes in Transmission Note Use Service Information in Function Group 40 as a reference To complete the Fault Code Check for Transmission per form the following 1 Check that no fault codes for the Transmission are saved in the Vehicle ECU 2 Write down any fault codes require correction Note Fault codes can also be traced using a diagnostic program run through a PC 2 4 Function Check of Parking Heater DANGER Check the heater and ensure that the exh
67. ppropriate service manuals where it concerns fault tracing repairs and maintenance of Volvo trucks In order to maintain the high standards of our literature your opinions and experience when using this manual would be greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via telefax or mailing directly to the address listed below To From Volvo Trucks North America Inc Dept 516 Service Publications 7900 National Service Road P O Box 26115 Greensboro NC 27402 6115 USA Fax 336 393 3170 Comments proposals 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 TSP158779 700 01 2002 Volvo Trucks North America Inc 2002
68. ration If there are other severe duty constraints for example driv ing in water lubricate more frequently up to once per day if necessary For further information on the T Ride Equalizer Beam L refer to 721 600 Rear Suspension T Ride W6000838 Cab Doors Door lock mechanism should be greased once per year using white lithium grease Coat the door stop arm with grease every year W8000949 Hood Hood lock lever front latch is coated with teflon and should not need any conventional lubrication If the mechanism is working hard or binds try cleaning first Clean and lubricate the scissor latch at the base cone receptacle with white grease W8000888 28 Group 177 Preventive Maintenance Preventive Maintenance Annual Service Including Lu brication and Oil Change Date Model Reg No Time Vehicle Identification Number Engine Dealer Code Transmission Name Rear Axle X Corrected without comment V Correction not needed Lubrication Oil and Fluid Level Check _ Chassis Lubrication Cab Lubrication Change Engine Oil and Filter Check Oil Level in Manual Transmission Check Oil Level in Automatic Transmission Check Oil Level in PTO Power Take Off Check Oil Level in Retarder Check Oil Level in Transfer Case O MAINI OI a AJOJN Check Oil Level in Front Drive Axle _ oO Check Oil Level in Rear Driv
69. released quickly and that no brake drag can be felt 103 Group 177 Preventive Maintenance 1 1 3 Check During Test Driving Check Clutch Operation During driving check for smooth operation and engage ment when shifting gears Look for uneven engagement and or unusual noise Wheel Brake Application and Release W5000617 DANGER To do the brake test safely make sure there are no other vehicles within 300 yards when testing or per form the test in a off road area where there is no traffic Performing brake test in traffic may lead to an accident personal injury or death During the first part of driving check the wheel brakes Check for even application and release Make sure the vehicle does not pull to the side when the brakes are ap plied and that the noise is not generated while braking Whether or not a truck is equipped with ABS brakes the bobtail proportioning valve will operate as designed reg ulating air brake pressure going to the rear wheel brakes while not hooked up to a semitrailer Rear wheels should not lock up during moderate braking when in bobtail mode Note The rear wheels may lock intermittently while driv ing unloaded under 30 km h 20 mph even when equipped with ABS brakes This is normal in unloaded operation 104 Group 177 TOOTHED HUB OR TOOTHED HUB OR TOOTH WHEEL TOOTH WHEEL HRR Cc N SENSOR i TRACTION CONTROL VALVE W
70. rnal Lamps 37 Check Rear View Mirrors and Reflectors 38 Function Check of Wipers and Washers 39 Check Headlamps 40 Check Air Filter for Ventilation System 41 Check Refrigerant Reservoir Condenser Pipes and Hoses 42 Check Air Intake and Air Deflector 43 Check Hood Attachment and Locking Devices gt RK Check Batteries Dirt Leakage Attachment Specific Gravity of Battery Acid Fluid Level Con nections and Battery Box 45 Check Fuel Tank Hoses Pipes Venting and Mounting 46 Check Filter for Fuel Tank Ventilation 47 Draining of Fuel Tank Dirt Water gt 8 Check Fuel Water Separator for the Fuel System Draining of Condensation Check Tire Wear Engine Compartment 50 Check Alternator Mounting 51 Check Electrical Connections and Cables for Al ternator Starter Motor and Preheater 52 Check Drive Belts 53 Check Air Compressor 54 Check Engine Mounting 55 Check Radiator Mounting 56 Check Radiator Fan Bearing Tolerance Bolt Unions Fan Cover and Fan Ring with Rubber Seal 57 Pressure Testing of Cooling System 58 Check Radiator Hoses Pipes and Air Flow 59 Check Intercooler Hoses Pipes and Air Flow Check Tightness of Engine and PTO 61 Check Fuel Lines on Engine 62 Check Exhaust Leakage 63 Check A C Compressor Mounting 64 Check A C Pipes and Hoses 65 Check Air Pipe between Air Intake and Turbo Check Turbocharger and Regulator 67 Check Pump Coupling for Injection Pump Elec tronic Engine
71. rrect procedure Caterpillar Long Life Coolant Change At every fourth year or 6000 hours of operation change coolant if long life coolant is used Use only clean water to flush out cooling system Re place the coolant filter at the same time 114 Every Two to Three Years Do not use a dryer cartridge for more than three years It may have to be changed before that If a large amount of fluid is collecting in the wet tank then the desiccant in the dryer may be saturated and needs to be changed Every Three Years Caterpillar Engine Compression Brake Slave Piston Lash If the engine is equipped with an engine compression brake adjust the slave piston lash after the engine valves are adjusted Make the adjustment with the en gine stopped Refer to the Caterpillar Service Manual for adjustment information Every Four Years Group 177 Additional Mileage Based Maintenance Eaton Fuller and Meritor Transmis sions Regular oil change intervals when petroleum oil is used are at every 80 000 km 50 000 miles See specification section for oil types and viscosities Caterpillar Initial Valve Lash Injector Preload Do an initial check on engine valve clearance and injec tor preload between 19 000 and 96 000 km 12 000 and 60 000 miles Adjust if necessary Volvo Transmission Regular oil change intervals for Volvo transmissions are at every 120 000 km 75
72. rvals for Volvo Components publication number 175 001 and appropriate vendor literature Volvo PTO s mount directly to the transmission and do not need separate oil fill and check Make sure there is extra oil filled in the transmission for the PTO volume Transmission oil heat exchanger should be installed when using PTO continuously over 15 minutes at a time or with a continuous power output over 55 kW 75 hp Without heat exchanger the oil can overheat WA000758 and transmission damage may follow If the application has a remotely installed pump or blower with a driveshaft connection the driveshaft U joints need to be greased at every maintenance interval or more of ten depending on usage Use a lithium based grease with EP additives and of the consistency of NLGI No 2 Driveshaft DANGER Failure to correctly grease the driveshaft U joints or slip joints can lead to component failure which can re sult in separation of the driveshaft from the vehicle A separated driveshaft can result in major component w4000753 damage and loss of vehicle control and can cause serious personal injury or death For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature Use a lithium based grease with EP additives with a consistency of NLGI No 2 Do not
73. s Check alignment and output of headlights W3000784 64 Group 177 u ee a m zx 6 W8000990 W8000989 W8000955 Preventive Maintenance 40 Check Air Filter for Ventilation System For further information concerning component specifica tions see service information in Group 8 and appropriate vendor literature The fresh air filter should be inspected every 64 000 km 40 000 miles for regular highway use In very dusty conditions it is recommended that the filter be checked every 16 000 km 10 000 miles Replace with a new fil ter every 113 000 km 70 000 miles Check that the evaporator drain nipple is open by squeezing the end to let water drain out If equipped check the bunk unit air filter located be hind the passenger seat on bunk support The bunk unit air filter should be inspected at regular intervals approxi mately every 112 654 km 70 000 miles The filter should be changed after 160 934 km 100 000 miles 65 Group 177 66 Preventive Maintenance 41 Check Refrigerant Reservoir Condenser Pipes and Hoses 08000117 Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death 1 Ensure that the Refrigerant Reservoir is filled 2 Using the l
74. s 71006749 A Fill Plug 50 Group 177 W4000749 W2001082 W8000899 Preventive Maintenance 1 5 Check Oil Level in Clutch Fluid Reservoir Note For further information refer to Clutch page 21 Check fluid level in the clutch fluid reservoir Add oil if necessary and use only DOT 4 SAE J 1703 fluid Replace clutch fluid every year to prevent corrosion problems in the system due to trapped moisture 1 6 Check Coolant Freeze Protection and Coolant Level Do not remove the cap to the coolant surge tank while the engine and radiator are still hot Scalding fluid and steam may be blown out under pressure if the cap is removed too soon Ensure that the coolant is not a long life product SCA cannot be added to this type of coolant Draw coolant for testing Adjust coolant as necessary and change the filter if needed Supplement coolant additive SCA level remain between 0 4 to 0 8 units liter 1 5 and 3 0 SCA units gallon See each engine manufacturer s recommendation for fil ter change intervals and additive replenishment 1 7 Check Fluid Levels in Windshield Wiper and Headlamp Wiper Reservoirs Check fluid level in the washer fluid container regularly Add if necessary 51 Group 177 52 W5001194 Preventive Maintenance 1 8 Check Air Dryer Air Dryers Air Dryers have internal maintenance systems that clean
75. s complete the following 1 Inspect the brake chambers and mounting brackets for wear and damage 2 To ensure correct brake balance all the brake chambers for each axle must be of the same size and type This balance will ensure maximum brake lining performance Group 177 Test Driving W4000760 W5000599 Preventive Maintenance 1 1 2 Check After Start Check Clutch Operation Start the test drive by checking clutch pedal play and clutch operation Clutch pedal play should be 4 to 10 mm 0 15 to 0 40 in which is the clearance between the pedal plunger and the piston in the master cylinder On vehicles with clutch brake check function by de pressing clutch pedal to within 6 to 12 mm 1 4 to 1 2 in from the floor while engaging a gear There should be no grating of the engagement teeth when the clutch brake is engaged Check Parking Brake and Clutch Slip Check for parking brake holding power and also for clutch slippage by engaging direct gear not allowing the engine speed to go above 1 000 rpm and attempt to drive off with the parking brake still applied The parking brake should hold the vehicle stationary while letting the clutch up slowly If the clutch slips or the truck moves forward during this operation note on form for later inspection of either the clutch or spring brake operation Release parking brake and start driving Check that the parking brakes are
76. s Not Applicable 30 Preventive Maintenance 1 Engine Compartment kei Check Tightness on Servo Pump Oil Lines and Steering Gear Check Sound Baffles for Engine Bi From suspension seine Sym cree m oresoon i 7 orea ron srao 7e enescsuengounke neun 7s cres Fon meoo p oarn E Check Front Wheel Bearings oo Check Front Wheels at ZI Checks Beneath the Vehicle Has 75 Check Tightness Bearing Clearance and Ventila tion on the Front Driving Axle 76 Check Clearance in Clutch s Mechanical Function 77 Check Clutch s Hydraulic and Pneumatic Control System 78 Check Clutch Wear 79 Check Transmission s Pneumatic and Mechanical Control System Check Seals for Speedometer Sensor and Joint Coupling 81 Check Tightness on Transmission Transfer Case and PTO Including check of lines 82 Check Tightness on Cooler for Transmission 83 Check Ventilation for Transmission Transfer Case and PTO 64 ones Tanne on ar eine os res Saura vane warme 07 ones one Bon or Poner Seer 88 Check Drive Shaft Universal Joints Sliding Joints and Support Bearings Check Tightness on Rear Drive Axles and Hub Reduction Gear Check Bearing Clearance for Pinion and Input Shaft to Rear Drive Axles I s2 ones Bas Pae mann oreo hear ung ws sow vs oem os et Rew Sodann 74 Group 177 Preventive Maintenance al Checks Beneath the Vehicle _ hes Checks Beneath the Vehicle nn 97 Check Bogie Lift or Lift Axl
77. ses complete the following e Inspect the charge air cooler for cracks Note Do not operate the vehicle with a damaged or bro ken charge air cooler This voids the warranty and the engine will not meet emission regulation requirements The best method to clean the package is to use air pres sure or water stream Clean from the back of the core Air pressure should not exceed 30 psi 200 kPa for radi ator and charge air cooler cores The use of fin comb is also a good tool to loosen bugs and dirt from the fins Note If the dirt cannot be cleaned off consult your Volvo Truck dealer 60 Check Tightness of Engine and PTO For further information refer to Group 4 To complete a check of the tightness of the engine and PTO complete the following 1 Check that the engine does not leak oil or coolant 2 Check that the fittings flanges and hose connec tions are tight 3 Check that hoses or pipes do not chaff or are cracked 4 Check that the PTO or lines do not leak oil Group 177 T1006751 W2000943 1 NA 2 Exhaust pressure governor 3 Oil delivery and return pipes 4 Clamp 5 Nuts Preventive Maintenance 61 Check Fuel Lines on Engine To complete a check of the fuel pipes and fuel lines complete the following 1 2 Check that the hose and pipe fittings for the fuel lines don t leak Check that the fuel lines do not leak or chaff
78. shroud Note The minimum clearance is 3 mm 0 12 in at any point around the fan ring 3 Loosen the belts and rotate the fan hub assembly Check for roughness and binding in the bearings Check that the end play does not exceed 1 5 mm 1 16 in 4 Check fan clutch for lining wear or air leaks Lubri cate fan hub if applicable 5 Inspect the idler pulley for cracks 6 Check for bearing roughness and binding 7 Inspect the belt driven water for bearing wobble and any evidence of leakage 8 Check the radiator package mounts bearing toler ance and bolt unions 9 Inspect rubber cushions for wear 10 Inspect fan shroud rubber molding and all fasteners for wear and tightness 57 Pressure Testing of Cooling System To complete a pressure test of the cooling system e Pressure test the cooling system using tool J 44399 z SI SEN gt W2001430 76 Group 177 NT fa ma ess i r y FN Ir m W2001496 Preventive Maintenance 58 Check Radiator Hoses Pipes and Air Flow Do not remove the cap from the coolant surge tank while the engine and radiator are still hot Scalding fluid and steam may be blown out by pressure if the cap is removed while the engine and radiator are hot Note This check is also considered Noise Emissions Control Maintenance which is required maintenance for any Volvo vehicle For furt
79. sing an ammeter test starter motor for maximum cur rent draw Check service manual for specifications Inspect mounting for secureness and for possible cracks around flanges Check wires for wear fraying and terminal tightness Make sure the wiring is properly routed and securely clamped Volvo Engine Preheater Inspect the Volvo engine preheater for correct function The ignition switch has a position in between the normal run position and the start position that engages the pre heater The engagement time is dependent on engine coolant temperature Above 10 C 50 F engagement time 0 seconds Between 10 to 15 C 50 to 4 F engagement time 25 2 to 55 2 seconds Below 15 C 4 F engagement time 55 seconds Note The preheat engages independent of the coolant temperature Group 177 W3000819 W3000818 W5000582 Preventive Maintenance 28 Check Pressure Regulator s Disconnection and Connection Pressure Pump the brake pedal while observing the air gauges As the air pressure is lowering verify the compressor governor cut in pressure and the low air warning switches cut in pressure Check that both indicator lights in the lower right corner and the Master Warning indica tor lights up and make sure the buzzer sounds Governor cut in should be at 790 35 kPa 115 5 psi The low air warning switches should close at a minimum pressure o
80. splay The display alternates between light and dark If any defects are noted cite them on the checklist Return the diagnostic display to the clock by pressing the MODE button five times To perform the ABS chuff test turn the ignition off Press down the foot brake and then turn the ignition back on again Listen through the side window that the ABS self check goes through the cycle twice Each pass oper ates the ABS modulator valves once which results in a brief puff of air being released from each valve The ABS indicator turns on and off twice and then remains on Note For vehicles with the Traction Control System TCS five chuffs occur for each valve If the vehicle is equipped with a Volvo engine the engine preheater indicator stays on three to four seconds If the coolant temperature is over 50 C 120 F the preheater is not engaged If the coolant temperature is below 50 C 120 F the preheater progressively engages longer depending on the coldness of the coolant If the indicator stays on there is a problem in the preheater circuit 53 Group 177 54 W2002673 Preventive Maintenance 20 Check for Fault Codes in the Vehicle Elec tronic Control Unit The instruments vehicle ECUs and engine ECUs are always included in the system Other included control units depend on the vehicle variant legal requirements and the vehicle specifications The control units are e Driver
81. stment need to be shown to the customer and scheduled for repair There are many time and or mileage based ser vice items that are not listed on the form Look at the end of this document for a listing of additional compo nents that may need to be serviced depending on the mileage or time since last service 4 General Maintenance Records It is important to use the inspection form together with other reports to come up with the best maintenance pro gram for a specific application Use driver s reports complaints parts usage repetitive failures previous re pair orders road failures etc to build a maintenance picture of the customer operation Records should be collected over the lifetime of the vehi cle to form a permanent vehicle record file The vehicle file should be used to customize the operational mainte nance needs The Driver Inspection Form is also required by Federal law The use of this inspection report makes the driver a part of the maintenance program and places direct re sponsibility on the driver to report problems that may come up during operation When properly used there should be no excuse for a defective vehicle being in ser vice Note The included Annual Service checklist is an uncontrolled copy The document may be updated without notice Annual Inspection Note For further information refer to Publication 177 500 Preventive Maintenance Basic Service VN VHD
82. sume accelerate and coast functions Verify that the cruise control is disengaged by the off switch clutch operation and brake application Check Steering System On the highway the steering should operate precisely and without shimmies tracking or vibration When oper ated at low speed and close quarters doing full turns the steering should operate without binding in any spot Check for Other Noise Check for unusual noise or vibration that can be con tributed to a problem Listen for unusual e Road noises e Wind noises e Mechanical noises 107 Group 177 Preventive Maintenance ED Check Instruments and Gauges EEE Ey ap SE ay TE Pe Sere S maa HHF 4 Check all instruments and gauges for proper function If possible check the odometer against a measured mile Check Heater and Air Conditioning 0077 Check function of heater and air conditioning Operate the controls and let the fan run on all speeds Note In the summertime the shut off valves for the heater may be closed for the season Open valves be fore testing heater W8000889 108 Group 177 W3000810 W6000829 W8000947 Preventive Maintenance 1 1 4 Check After Test Driving Check Pneumatic Switches If vehicle is equipped with a pneumatic 5th wheel slid
83. the right side of the bell housing Grease the release bearing but do not overgrease Driveshafts When greasing a driveshaft U joint it is very important that grease comes out of each of the four bearings If grease does not come out of a seal press the shaft to ward the seal and apply grease at full pressure If a U joint can not be fully greased note it on the form for further inspection An ungreased U joint bearing will fail after a short time If vehicle is equipped with a PTO that has a driveshaft lubricate its U joints Volvo T Ride 1 Remove the pressure relief valve located at A and install a grease fitting Remove the grease fitting at B Fill with grease through A fitting until grease oozes out of B 4 Install the grease fitting at B and fill it with grease until it oozes out around the entire seal See arrow 5 Remove the grease fitting at A and reinstall the pressure relief valve The bearing must be completely filled with grease This becomes very important if vehicle operates in wet areas If operating in places where driving through water lubri cate daily to force water out of bearing area 37 Group 177 W9000074 W8000949 W6000843 38 Preventive Maintenance 2 Cab Lubrication Fifth Wheel Note For further information refer to Cab page 28 Lubricate the plate pivot points and slide mechanism Apply a he
84. the transmission Also check for excessive dirt wear or damage e Check that the oil lines are secure and free from ex cessive dirt wear or damage e Ensure that the steering gear is secure and free W6001428 from excessive play e Check that the power steering pump is securely fas tened to the engine e Ensure that the power steering hoses are secured and free of leaks 69 Check Sound Baffles for Engine This option not applicable to the VN VHD vehicles 82 Group 177 Preventive Maintenance Front Suspension Steering System Checks 70 Check Steering Linkage To perform a check of the servo pump and steering gear complete the following 1 Check the steering shaft drag link and tie rod In spect for damage or external wear 2 Check joints for play by manually pushing and pulling each ball stud 71 Check Front Shock Absorbers To perform a check of the front shock absorbers com plete the following 1 Check the rubber mounting bushings for wear or damage 2 Disconnect the lower end and work the shock ab sorber by hand to see that the outer tube is not striking or rubbing against the fluid reservoir tube 3 While the shock absorber is disconnected check the piston movement by pulling and pushing the ab sorber down and up slowly to insure the piston does not bind in the pressure tube Note There should be considerable resistance w124 When extending the
85. the upper adjusting screw 1b in the pedal carrier Fig 1 Clutch W4000756 Design and Function 21 Group 177 Volvo Clutch Slave Cylinder Slave cylinder stroke A is 29 1 mm 1 14 0 04 in The clutch pedal throw 2 see previous illustration gives the stroke The lower adjusting screw 2a limits the pedal throw and thereby the clutch slave cylinder stroke Distance B should never be exceeded The distance is adjusted by removing the fork from the lever and reposi tion lever on the cross shaft Distance C is set when the clutch is new During wear of clutch the distance will decrease Readjustment should not be needed before it is time to reface the clutch disc Other Clutch Slave Cylinder A slave cylinder for any non Volvo clutch has a wear in dicator When the indicator is out of the operating range it is time to adjust the clutch To get the slave cylinder throw into the accepted range adjust the clutch plate until the indicator is in the operat ing range again 22 Design and Function W4000731 Fig 2 Volvo Clutch Slave Cylinder W4002441 Slave Cylinder Mounting Bolts Clutch Clevis Pin Clutch Master Cylinder and Reservoir Found on the Bulkhead in the Engine Coupling Group 177 Design and Function Power Take off Volvo PTO For further information concerning component specifica Zo tions see service information in Group 1 Oil and Filter A Change Inte
86. to assure the designed life expectancy of the vehicle and its individual components W9000073 Maintenance Coverage There is no firm maintenance program that will apply to all operations A basic maintenance program is not diffi cult to set up to make the program the most effective takes time and effort and is based around the needs and experiences of each individual operation The pro gram in this service manual covers all types of Volvo VN VHD vehicles with medium to high mileages and sometimes high loads Use this established maintenance program as a base to tailor an individual maintenance program for customers that have requirements that are outside of the scope of this program To establish an individual program look at information sources that are usually available such as Drivers repair or complaint reports Unusual parts usage Repetitive failures or problems found in inspection Unscheduled maintenance or repairs Road failures Group 177 Program Structure This maintenance program has been based on the progress in vehicle technology and increases in oil qual ity to simplify the maintenance For simplified scheduling the program has tied mainte nance to logical time or mileage limits that make it easy to anticipate needed servicing For the majority of on highway operators the 24 000 km 15 000 miles or 4 months schedule can be used with little change It is important that the scheduled interva
87. use conventional chassis grease The driveshaft U joints must be lubricated correctly for the bearings to receive grease The most common case of U joint failure is incorrect greasing Always make sure that grease is coming out of all four seals If one seal fails to purge old grease move the driveshaft from side to side while applying gun pressure This allows for greater clearance on the thrust end of the bearing that is not purging New grease flushes abrasive contaminants from each bearing and assures that the bearing is filled properly 23 Group 177 Brakes Brake Cams and Slack Adjusters For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature For further information concerning brake cams see ser vice information in Group 5 Q Plus LX500 and MX500 Cam Brakes Literature publication number 514 003 and appropriate vendor literature Lubricate the brake cam bushings using a lithium based grease with EP additives and consistency NLGI No 2 Fill grease until old grease has been pushed out past the seal and new grease can be seen flowing Lubricate the slack adjusters using a lithium based grease with EP additives and consistency NLGI No 2 Fill grease until old grease has been pushed out past the splined shaft area and adjustment pawl and new grease can
88. ve gloves and glasses when changing oil Hot oil can cause severe burns Check the oil level through the top plug The oil should be level with the hole Add oil if necessary Drain oil through the bottom plug Drain oil immediately after driving the vehicle so that the oil is hot Note Also check the rear axle ventilation for blockage Blockage can cause extreme pressure in the axle and create leaks Hub Reduction For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components publication number 175 001 and appropriate vendor literature If the axle is equipped with hub reduction empty each hub separately when changing oil Turn the wheel until the drain plug is at it s lowest position Remove plug and drain Fill oil through the level fill plug hole Fill each hub reduc tion before filling oil in the rear axle Note Synthetic oil is not recommended for the Volvo transmissions Note Independent shift units require an lubrication check independent of the axle lubrication check Group 177 Preventive Maintenance 1 1 Check Oil Level in Hydraulic Bogie Lift MAX MIN This option not available on VN VHD vehicles T1006404 A Drain Plug B Filler Plug 1 2 Check Oil Level in Power Steering For further information concerning component specifica tions see service information in Grou
89. when entering or exiting Make sure the soles of your shoes and the cab steps are free from dirt grease oil or moisture before using the steps Failure to do so can result in a fall and serious personal injury or death may occur General DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death DANGER If using a jack and or jack stands choose proper fault free equipment Failure to do so can result in equipment failures and personal injury or death may occur Note During the Preventive Maintenance inspection check the condition of warning labels on the vehicle If a label is damaged or defaced to the point where the mes sage cannot be read note on the inspection form to have it replaced Group 177 Specifications Specifications Engines General For further information concerning component specifica tions see service information in Group 1 Oil and Filter Change Intervals for Volvo Components Publication Number 175 001 and appropriate vendor literature In a modern diesel engine it is very important to have regular oil changes The demands of pulling high loads pulling at high elevations extreme high or low tempera tures and longer service intervals make the choice of correct oil a hard task The Volvo dealer the engine m
90. wice Consistency is important to maintaining accuracy of the reading If inconsistent readings persist check the transmission breather to be sure it is clean and unclogged Group 177 Preventive Maintenance Cold Check Note The fluid level rises as its temperature rises Do not fill above the Cold Run band if the transmission fluid is below normal operating temperatures 1 The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made 2 Run the engine for at least one minute Apply ser vice brake Shift to Drive D and operate the engine for 30 seconds at 1000 to 1500 rpm then shift to Reverse R to clear the hydraulic system of air Then shift to Neutral N and allow the engine to idle 500 to 800 rpm 3 With the engine running remove the dipstick from the tube and wipe clean 4 Insert the dipstick into the tube and remove Check the fluid level reading Repeat the check procedure to verify reading 5 Ifthe fluid level is within the COLD RUN band the transmission may be operated until the fluid is hot enough to perform a HOT RUN check If the fluid level is not within the COLD RUN band add or drain as necessary to bring it to the middle of the COLD RUN band 6 Perform a hot check at the first opportunity after the normal operating temperature of 71 93 C 160 200 F is reached 43 Group 177 44
91. y 111 Group 177 W1000064 W1000061 112 Preventive Maintenance 1 1 5 Finish Drive Vehicle Check Fluids Drive the vehicle around the block to settle the oil and to verify any points that were found during the inspection Check all fluid levels Make sure there are no signs of leakage after changing oils or filters Clean Clean all areas that have been dirtied during the test drive As a courtesy to the customer be especially care ful about making sure the cab area is as clean or cleaner than when the vehicle came into the shop Attach a new maintenance sticker Group 177 Additional Time Based Maintenance Volvo Engine Check the engine valve clearance after the first six months of operation Check every 12 months or 193 121 km 120 000 miles thereafter Adjust if necessary Engine Coolant Engine coolant needs to be changed every two years unless the maximum mileage has been reached before that See specification section for engine manufacturer s mileage recommendation Texaco Extended Life Coolant Note For further information on long life coolant refer to Service Bulletin 260 002 Texaco Extended Life Coolant Long life coolant is colored red for identification pur poses so as not to mistake it for conventional green coolant Long life coolant will test as out of additives SCA but SCA should not be added Fleetgaurd ES Complete

Service Manual - Preventive Maintenance

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