Volvo Maintenance Manual (EN)

Foreword This manual contains information concerning the safe operation of your vehicle. It is extremely important that this information is read and understood before the vehicle is operated. This manual also contains a considerable amount of information concerning the vehicle, such as vehicle identification, Preventive Maintenance recommendations and a log for your service records. Please keep this in the vehicle at all times. Information from other component manufacturers is supplied in separate manuals in the Owner’s Package. Note: It is important that this manual stays with the vehicle when it is sold. Important safety information must be passed on to the new customer.

The service information contained in this manual gives the owner important information about maintaining the vehicle but is not intended as a substitute for the Preventive Maintenance Service Manual and must not be regarded as such. The National Highway Traffic Safety Administration (NHTSA) and Volvo Trucks North America, Inc. should be informed immediately if you believe that the vehicle has a defect that could cause a crash, injury or death. Contact NHTSA by calling the Auto Safety Hotline at 1 (888) 327–4236 or by writing to: NHTSA, U.S. Department of Transportation, Washington, DC 20590. Volvo Trucks North America, Inc. Greensboro, NC USA Order number:

PV776-2 0707967 © 2004 Volvo Trucks North America, Inc., Greensboro, NC USA All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..

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Contents General Information .............................. 1 Information For the Owner .................... 1 Fuel Safety Reminders ........................ 52 Diesel Fuel Specification ..................... 53 Fuel Additives ..................................... 57 Alternative Fuels ................................. 59 Safety Information ................................. 3 Proper Maintenance Procedure ............. 3 Injury Prevention ................................... 6 Engine Damage Prevention ................. 15 Electric System Damage Prevention ... 17 Reporting Safety Defects ..................... 19 Speed Restrictive Tires ........................

20 Oil System ............................................. 60 Engine Oil ............................................ 60 Service Schedules VN, VHD ............... 68 ............................................................. 68 General Engine Design Information .. 21 Engine Overview, VN D12D (Volvo V-Pulse)Right Hand View ................... 21 Engine Overview, VN D12D (Volvo V-Pulse)Left Hand View ..................... 22 Engine Overview, VHD D12D (Volvo V-Pulse)Right Hand View ....... 23 Engine Overview, VHD D12D (Volvo V-Pulse)Left Hand View ......... 24 Engine Features ................................... 25 Engine Features Continued .................

26 VECTRO III Customer Parameter Values, D12D ....................................... 27 Engine Variants, D12D ........................ 30 Engine Data ......................................... 32 Maintenance ......................................... 73 Exhaust and Noise Emissions .............. 73 Flushing Cooling System, D12D ......... 96 Turbo and Charge Air Cooler .............. 98 Replacing Fuel Filters ....................... 100 Fuel System Service .......................... 101 Transmission and Rear Axle Maintenance ...................................... 108 Steering and Brakes Maintenance ..... 112 Electrical System Maintenance ......... 120 Tires, Wheels and Hub Maintenance .

126 Chassis Maintenance ......................... 131 Cab Maintenance ............................... 133 Lubrication VN, VHD ....................... 139 Viscosity and Capacity Tables ........... 142 Engine Storage ..................................... 33 Engine Storage .................................... 33 Literature ............................................ 147 Service Assistance and Manuals ....... 147 Cooling System ..................................... 35 General Coolant Information ............... 35 Water Specification .............................. 42 Additives .............................................. 43 Antifreeze ............................................

44 Service Charts .................................... 149 Scheduled Services ............................ 149 Repair Record .................................... 152 Tire Record ........................................ 157 Fuel and Oil Record .......................... 168 Fuel System ........................................... 52 Index .................................................... 177

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Warning Label Information IMPORTANT Before driving this vehicle, be certain that you have read and that you fully understand each and every step of the driving and handling information in this Operator’s Manual. Be certain that you fully understand and follow all safety warnings. IT IS IMPORTANT THAT THE FOLLOWING INFORMATION CONCERNING LABELS IS READ, UNDERSTOOD AND ALWAYS FOLLOWED. Note: A note defines an operating procedure, practice, condition, etc., which is essential to the proper operation of the vehicle. The following types of labels are used throughout this manual:

DANGER A danger label directs the operator’s attention to unsafe practices which could result in serious personal injury or death. The danger label is in white type on a black background with a black border. WARNING A warning label directs the operator’s attention to unsafe practices which could result in personal injury or severe damage to the vehicle. The warning label is in black type on a gray background with a black border. CAUTION A caution label directs the operator’s attention to unsafe practices where personal injury is not likely but property damage could occur. The caution label is in black type on a white background with a black border.

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General Information 1 Information For the Owner If there are questions on the maintenance and performance of your vehicle, please discuss them with your Volvo Truck dealer. Your authorized dealer is required to have trained mechanics, special tools and spare parts to fully service your vehicle. If necessary, your dealer will contact Volvo Trucks North America or other manufacturers for any assistance. Establish a Preventive Maintenance Program with the help of your local Volvo Truck dealer. A Preventive Maintenance Program makes it possible to maximize the amount of time your vehicle is up and running, resulting in longer component life.

This makes for a safer vehicle by reducing any mechanical failures due to poor maintenance practices. In addition to this Maintenance Manual, there may be additional instruction/operator’s manuals supplied by component manufacturers. These manuals are placed in the Owner’s Package and placed in the cab. Be sure to read all the manuals thoroughly before operating the vehicle. Note: Federal law requires manufacturers to notify owners of its products in the event of a Federal Motor Vehicle Safety Standard or if a safety related defect is discovered.

If you are not the original owner of this vehicle, please notify us about the change in ownership at the address below or through an authorized Volvo Truck dealer. This is the only way we will be able to contact you if necessary. Also, various safety labels may be placed on components by the component manufacturer. Be sure to read and follow these labels to prevent damage to the vehicle, personal injury or even death. Volvo Trucks North America, Inc. P. O. Box 26115 Greensboro, NC 27402–6115 Information in this manual refers to Volvo components and Volvo drivetrain. There is also certain information regarding the Cummins engine.

For detailed information on the Cummins engine or non-Volvo engines and/or drivetrains contact the respective manufacturer. United States of America

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