volvo Trucks Service Manual (EN)

Foreword The descriptions and service procedures contained in this manual are based on de- signs and methods studies carried out up to December 2001. 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.

Greensboro, NC USA Order number: PV776-TSP151476 © 2001 Volvo Trucks North America, Inc., Greensboro, NC USA All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, me- chanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..

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Contents General .................................................................................................... 3 Preventive Maintenance, General ........................................................... 3 Safety Advice ......................................................................................... 7 Specifications ......................................................................................... 9 Engine .................................................................................................... 9 Transmission ........................................................................................

12 Rear Axle ............................................................................................. 13 Tools ...................................................................................................... 14 Special Tools and Special Equipment ................................................. 14 Preventive Maintenance Inspection Bay ............................................. 21 Design and Function ........................................................................... 23 Clutch ...................................................................................................

23 Power Take-off ..................................................................................... 25 Driveshaft ............................................................................................. 25 Brakes .................................................................................................. 26 Steering System .................................................................................. 27 Hubs .................................................................................................... 28 Chassis ................................................................................................

29 Cab ...................................................................................................... 30 Preventive Maintenance ...................................................................... 31 Basic Service ....................................................................................... 31 ............................................................................................................... 97 Additional Time Based Maintenance ..................................................... 97 ...............................................................................................................

99 Additional Mileage Based Maintenance ................................................ 99 Feedback 1

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Group 177 General General Preventive Maintenance, General Introduction Maintenance Coverage This manual describes inspection and lubrication re- quirements during the Basic Service of Volvo VN/VHD vehicles. The purpose for doing the preventive mainte- nance is to ensure that the vehicle is safe and roadworthy over its full lifetime. 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 mileage and sometimes high loads. 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.

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: 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 mileage.

Good maintenance is necessary to assure the designed life expectancy of the vehicle and its individual components. Driver’s repair or complaint reports. Unusual parts usage. Repetitive failures or problems found in inspection. Unscheduled maintenance or repairs. Road failures. 3

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