Volvo D11F manual

V olvo T rucks. Driving Suc cess. R OPER A TOR'S MANUAL VEHICLE MAINTENANCE VN,VHD Vol vo d11f and d13f engine s[...]

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Table of Contents i Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Warning Label Information . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Information for the Owner . . . . . . . . . . . . . . . . . . . . .[...]

ii Table of Con tents Service Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Service Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Scheduled Services . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Forew ord 1 FOREWORD DO NO T Remove this m anual from t he v ehicle. It contains i m portant operational and safety informatio n that is needed by all dri vers and owners of this vehicle. This manual contains information concerning the safe o p eration of your vehicle. It is e xtremely important that this inform ation is read and understood before [...]

2 Forew ord WARNING LABEL INFORMATION IMPOR T ANT : Bef ore dri v ing this vehicle, be certain that you hav e read and that y ou fully understand each and every step of the driving a nd handling information in this Operator' s Manual. Be certain that yo u fully understand and follow all safety warnings. It is extremely important that this info[...]

Gener al Info rmation 3 GENERAL INFORMATION INFORMATION FOR THE OWNER If there are qu es tions on th e maintenan ce and performance o f your v ehicle, plea se disc uss the m with your V olvo Truc k dealer . Y our authorized dealer is required to h ave trained mech anics , sp ecial tools and spare parts to fully service your v ehicle. If necessary ,[...]

4 Gen eral In forma tion This Maintenance Manual co vers all V o lv o veh icles manufactured b y V olvo T rucks North America, including the wh ole chassis and all V olvo manufactured co mponents. For specif i c maintenance information on vendor components, man u factur ed by , for e xam ple: Cumm ins, Fuller , Meritor , etc., see the respectiv e m[...]

Gener al Info rmation 5 EXHAUST AND NOISE EM ISSIONS General USA The Federal Clean Air Act, Section 203 (a) (3), stat es the foll owi ng concerning the remo val of air pollution control devices or mo difi cation of a certif ied engine to a non-certif ied configuration : “The follo wing acts and the causing thereof are pro h ibited: (3) F or an y [...]

6 Gen eral In forma tion CALIFORNIA EMISSION CONTROL SYSTEMS WARRANTY W arranty cov erage is subject to change withou t notice. Contact you r V olvo T ruck dealer for the curre nt warranty statement. The Calif o rnia A ir Resource s Board and V olvo T rucks North America are pleased to explain the California emiss ion control system w arranty on yo[...]

Gener al Info rmation 7 If you h ave an y questions regarding y our warranty rights and respons ibilities, you sho uld contact t he V olvo T rucks No rth A merica W arranty Department at P . O. Box 26 115, Greensboro , NC 27402-6115, o r the Californi a Air Resources Board at 9480 T elstar A venue, El Monte, Californi a 91731. (Applicable only to v[...]

8 Gen eral In forma tion PROCEDURES F OR HANDLING E MISSIONS CONT ROL SYSTEM WA RRANTY The follo wing engine components are co vered by the supplemental emis s ions control s y stem w arranty polic y as required b y the Californ ia Code of Regulation s. a. T urbochar g er Assembly b . VGT Actuator Control V alve c. Charge Air Co oler d. Unit Inject[...]

Gener al Info rmation 9 The emission w arranty for the diesel particulate f il ter co vers defects in workmanship only . Normal maintenance, such as cleaning ash fr om the filter at regular maintenance interv als, is not covered b y th e emission warranty . In response to cu s tomer req u ests, V olvo T rucks North Amer ica may b uild vehicl es wi [...]

10 Gen eral In forma tion In the e vent that dama ge r esults f r om unautho rized adjus tments to any emission contr ol system compon ents, as evi denced by s et ting s other than as specif i ed, or br oken fastener seals, the cost of r epairing such damag e WILL NO T BE CO VERED under wa r ra nty . 3. Repairs by Non-VO LVO Facilities Owners may e[...]

Gener al Info rmation 11 7. Customer Assistance V olvo T rucks North America wishes to ass u re that the Calif o rnia Emission Control Sys tems W arranty is properly administered. I n the ev ent that ow ners do not recei ve the warr anty service to which they believ e they are entitled under the Cali fornia Emission Control Systems W arranty , they[...]

12 Gen eral In forma tion CALIFORNIA EMISS ION CONTROL SYSTEMS SERVICE RECORD CALIFORNIA EMISSION CONTROL SYSTEMS SERVICE RECORD D A TE KMMILES SER VICE PERFORMED SER VICED BY __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/_ _/__ __/[...]

Gener al Info rmation 13 GASEOUS EMISSION CO NTROL SYSTEMS WARRANTY For emis sion contr ol sys tems infor matio n on e ngine s ot her th an VOL VO, refe r to the eng ine vendor’ s publicatio ns. V olvo T rucks North America war rants the Emission Control Systems on each ne w VOL VO d iesel engine in a new V OL VO truck to comply with all United S[...]

14 Gen eral In forma tion ENGINE GASEOUS EMISSIONS CONTROL SYSTEM WARRANTY FEDERAL E MISSION REQUIR EMENTS The follo wing engine components are co vered by the supplemental emis s ions control s ystem warrant y polic y as required b y the Federal emi ssions re gulation s. a. T urbochar g er Assembly b . VGT Actuator Control V alve c. Charge Air Co [...]

Gener al Info rmation 15 The emission w arranty for the diesel particulate f il ter co vers defects in workmanship only . Normal maintenance, such as cleaning ash fr om the filter at regular maintenance interv als, is not covered b y th e emission warranty . In response to cu s tomer req u ests, V olvo T rucks North Amer ica may b uild vehicl es wi[...]

16 Gen eral In forma tion ENGINES OTH ER THAN VOLVO Fo r sp ecif ic information on engines other t han V OL V O, refer to t he engine vendor’s publications. Noise Emissions V olvo T ru cks North America warrants to the first person who purchases this vehicle fo r purposes other than resale and to each subsequent purchas er , that this v ehicle as[...]

Gener al Info rmation 17 Tamper ing with Noise Contro l Syste m Federal law prohibits the following acts or the causing thereof: (1) The remo val or rendering inoper at i ve b y an y person, other than for purposes of main t enance, repair , or replacement, of an y devi ce or element of design incorpo rated into any ne w vehicle f o r the purpo s e[...]

18 Gen eral In forma tion Regulatory C ompliance Acts that constitute tamperin g with the Noise Shielding and In sulation Dev i ces: Remo ving or render ing inoper ativ e the engine and/o r transmissio n noise deadening panels, shields or in sulating materials. Remo ving or render ing inoper ativ e the cab-tunnel o r hood noise ins ulating material[...]

Gener al Info rmation 19 Exhaust S ystem Hot engine! A void all movable pa rts or hot engine part s, exhaust gases , and/or fluids . A hot engine, exhaust, and /or fluids can cause burns. Mainte nance Make sure the exhaust system is intact. Inspect for damage, m isalignment and/ or leakage. Primary system componen t s requiring noise relat ed inspe[...]

20 Gen eral In forma tion Engi ne Control, EGR and Fuel Sy stems Acts that constitute tamperin g with Engine Control, EGR and Fuel Systems: Remo ving rendering inop erati ve, or modi fying the engine control system such as the ECU, EGR system compo n ents, or fuel system compo nents, in order to allow th e engine to operate outside of the manufactu[...]

Gener al Info rmation 21 LABEL INFORMATION VT Shown, VN a nd VHD Similar 1. T ransmissi on T ype and Gear Pat tern This inf ormation is located in the visor . 2. VIN/GA WR Located in the door frame “B” pillar . 3. VIN/Major Components Located in the doo r frame “B” pillar . 4. V ehicle Noise Emi ssion Located in the doo r frame “B” pill[...]

22 Gen eral In forma tion FUSE AND RELAY LOCATION Always replace fuse s and circuit br eakers with the same current/ amperage. Incr easing fuse or circuit b r eaker rating may r es ult in electrical circuit o verheating and possible f ire. On sleeper mode ls equipped wi th fl uor escent lighting, ther e is a 3 AMP maxi mum fu se lo cat ed in the li[...]

Gener al Info rmation 23 The fuse re lay panel is located under t he top cover of the dash board. The vehicle has an electrical center located in th e midd le o f the dash under the top cov er . Since the function of s ome fuses or relays may change for the v ehicle application, refer to the list of functions th at is attached beneath each panel. V[...]

24 Safe ty In forma tion SAFETY INFORMA TION PROPER MAINTENANCE PROCEDURE Before w orkin g on a v ehicle, set the parking brak es, place the transmission in neutral, and chock the wheels. F ailure to do so can result in unexpected v ehicle mo vement and can cause ser ious personal i njury or deat h. Exhaus t gase s contai n carbo n monoxid e. Alway[...]

Safety Information 25 During Maintenance Remov e ke y from ignition w hile working on v ehicle or engin e. DO NO T allow unauthorized personnel on, around or in the v ehicle when maintenance or r e pair is being performed. 앫 When opera t ing the e ngine in an encl osed area, v ent the exhaust to the outside. 앫 Before ser vicing your v ehicle, a[...]

26 Safe ty In forma tion Compressed Air and Water Compr essed ai r can cause serious p ersona l injury. When usin g compr essed air fo r cleaning, wear a protectiv e face shield, protective clothing and protective shoes. Pressurized water could cause particles and/or hot water to be sprayed in your direction and ca use perso nal injury. The maximum[...]

Safety Information 27 DO NO T raise the engine hood if y ou see or hear steam or coolant escaping fr om the engi ne compartment. W ait until steam or coolant cann ot be see n or heard an y longe r bef ore raising the hood. DO NO T remove the co o lant f ill cap if the coolant in the surge tank is boiling. Also, do not remove the cap while the engin[...]

28 Safe ty In forma tion T o prev en t personal injury , do not climb up on the engine to remove t he f iller cap. Use a suitable, properly positioned ladder to reach the cap. At normal operating temper ature, the engine coo lant is very ho t and under pressure. If pressure is relie ved rapidly in a hot cooling system, the hot coolant can turn into[...]

Safety Information 29 Speed Restricti ve Tires Operating a v ehicle equipped with speed restrictiv e tires in excess of their stated rating may result in tread separatio n and/or blow out result ing in the loss of steerin g control and possib le collision. Seriou s personal inj ury or death could occ ur . Alway s maintain proper air pressure and ne[...]

30 Safe ty In forma tion DO NO T service any part of the fuel system while smoking or in the presence of flames , sparks or hot su r faces. F ailure to follo w these precautions can res ult in fire, which can cause serious inju ry or death. DO NO T stor e fuel containers in the vehicle. They may leak, explode and cause or feed a f ire. E mpty or fu[...]

Safety Information 31 DO NO T expo se the engine to flames, driv ing ov er burning ground. DO NO T weld or flame cut on or around pipes or tubes that contain flammable fluids. Exhaust heat shields ma y be installed to protect oil or fuel carrying lines and pipes from hot exhaus t parts . T o protect from pipe or seal f ailure, install heat shields [...]

32 Safe ty In forma tion Fire Exting uisher Anytime work is being done to the fu el system o r any o ther area where flammable substances are being used, ha ve a f ire extinguishe r av ailable and kno w ho w to use it. Inspect and ha ve it serviced as recomm ended on its instruction labe l. Respi rato ry Hazar d Prevention Exhaus t gase s contai n [...]

Safety Information 33 Crushing or Cuttin g Preve ntion Before w orkin g on a v ehicle, set the parking brak es, place the transmission in neutral and chock the wheels. F ailure to do so can res ult in unexpected ve h icle mo vement and can cause serious personal injury or death. DO NO T work near the fan with the engine running or the ignition in t[...]

34 Safe ty In forma tion Clim bing Up an d Down Always have th ree limbs (one fo ot and two han ds or two feet and one h and) in contact with the vehicle at all tim es w hen entering or exiting the cab or the area behind the cab. F ailure to follo w this warning can result in ser ious pers onal in jury or deat h. DO NO T climb up on or jump o ff fr[...]

Safety Information 35 Engine Starting DO NO T start the engine or mo ve an y of the controls or disengag e the parking brake if the warn ing tag “DO NO T OPERA TE” is attached to the ign ition ke y or located on t he dash. Check with the person w ho attached the tag before starti ng. Make su re no one is worki ng on or cl ose to t he engine or [...]

36 Safe ty In forma tion ELECTRI C SYS TEM DAMAGE PREVEN TION Electric and Electroni c Systems Always wear eye pr otection when working ar ound batteries to pre vent the risk of injury due to contact wi th sulfuric ac id or an explosion. Ne ver d i sconnect an y charging unit circuit or battery circuit cable fr om the battery when the ch arging uni[...]

Safety Information 37 Elect roni c Engin e Contr o l Sy stem The engine uses high voltage to the electronic unit injectors. DO NO T come i n contact with the unit i njector terminals w hile the engine is running. An electric shock can caus e an in voluntary muscle spasm and cause los s of b alance and falls l eading to sev ere personal inju ry or d[...]

38 Safe ty In forma tion REPORTING SAFETY DE FECTS USA The National Highway T raff ic Safety Administration (NHTSA) and V olvo T rucks North Ameri ca should be i n formed immediately if yo u believ e that the vehicle has a defect that could cause a vehicle accident, injury or death. Contact NHTSA by calling the Auto Safety Hotline at 1 (888) 327-42[...]

General Engine Informatio n 39 GENERAL ENGINE INFORMATION ENGINE OVERV IEW, D11F AND D13F LEFT SIDE VIEW D13F Engi ne Shown, D11F Engi ne Sim ilar 1. B reat her T ube 2. Inta ke M ani fold 3. Air C omp ress or 4. Power Steering Pump 5. Fuel Pump 6. Engine Electroni c Control U nit (EECU) 7. Fuel Filter 8. Fuel/W ater Separator 9. Fuel Filter 10. Ha[...]

40 General Engi ne Information ENGINE OVERVIEW, D11F AN D D13F RIGHT SIDE VIEW D13F Engi ne Shown, D11F Engi ne Sim ilar ENGINE STORAGE 17. Exhaust Manifold 18. V a lve Cover 19. Engine Pre-Heater Element (Optional) 20. Thermos tat Housing 21. Belt T ensioner 22. Coolant Pump 23. Coolant Filter 24. V enturi Pipe 25. Oil Filters 26. Oil P an 27. EGR[...]

Engine Storage 41 ENGI NE STORA GE If the v ehicle must be parked f or a period (mo re than 30 day s), protect it as follows: 1. Drain the engine o i l. 2. Fill up to the proper level with oil of the recommended qualit y and viscosity. 3. Fill up the fu el tanks with the r ecommended grade of fuel. 4. Run the engine for t wo minutes around 1000 rpm[...]

42 Maintenance and Service MAINTENANCE HAZA RDS Before working on or inspectin g a v ehi cle, set the parking brak es, place the transmissi on in neutral and chock the wheels. F ailur e to do so can result in unexpected vehicle mo vement and can cause seri ous per sonal inju ry or death. DO NO T attempt to repair or service this vehicle without hav[...]

Maintenance and Service 43 ENGINE COMPON ENTS, SERVICE SCHE DULES Component O peration Km (M iles)/M aximu m Months/ Hour s Fuel Filter — All Engin e Models Change Each o il change* W ater Separator — All Engin e Models Filter c hange Each oil change* Air Filter — US07 Change Control lamp indication/ 24 months Air Filter — Euro 4 Chang e At[...]

44 Maintenance and Service COOLIN G SYSTEM General Coolant Inf ormation Coola nt is toxi c; risk of po isoning. DO NO T drink coolant . U se proper hand protection wh en handling. Keep coolant out of reach of children and animals. F ailure to follow these precautio ns can cause serious ill ness or death. DO NO T raise the engine hood if y ou see or[...]

Maintenance and Service 45 In addition to t his, the coo lant must: 앫 Protect against pitting and cavitation erosion damage of the water pump and cy li nder lin ers. 앫 Protect against freezing and boiling. 앫 Pre vent formati o n of scale, sludge depos its and clogging . 앫 Be harmless to poly mer materials and seals in th e cooling system. ?[...]

46 Maintenance and Service DO NO T use antifreeze formulated for au t omobile gasoline engines. T h ese hav e a very high silicate content that will clog the radiator and lea ve unwanted deposits in the engine. A well functioning and main tained cooling system is as import ant to the engine as p erforming re gular o i l changes or using good fuel. [...]

Maintenance and Service 47 Never add coolant to a h ot or overheated eng ine. Engin e dama ge can r esult. Allow the engine to cool f irst. Additives Additi ves help prev ent rust, scale and min eral deposits from f orming. Additi ves also protect metals from corrosion, pre vent w ater pump and cyl inder liner ca vitation and contai n anti-foaming [...]

48 Maintenance and Service Extended Lif e Coolant Change Inter val Extended life cool ant will test a s out of a dditives (SCA), but SCA s hould not be added. Sh ortened engine lif e may be the res ult of add i ng S CA. Replace coolant e very 960 000 km (600,0 00 miles), 12,000 ho urs or ev ery four years , whichever comes first. An e x tend er pac[...]

Maintenance and Service 49 FUEL SYSTEM Fuel Safety Reminders A diesel engine w ill operate on a ny fuel which enters the cylind er , whether it is from the injectors or from the air intak e system. Therefor e, if any solvent is used to flush ou t the air cleaner element, the engine may ov er speed durin g star t-up. E ngine d amage, sever e perso n[...]

50 Maintenance and Service Diesel Fuel Specificat ion Quality Diesel engi nes for 2007 and later model y ear vehicles ar e designed to oper ate only with Ultra Low Sulfur Diesel (ULS D) fuel. Use of fuel other than ULSD will r ed uce the ef ficiency and durability of the engine, permanently damage the advanced emi ssion contr ol syst ems, r educe f[...]

Maintenance and Service 51 Fuel Su lfur Co ntent Fuel sold for use in diesel-po wered eng ines fo r 2007 and l ater model year ve hicles may o nly contai n a maximu m sulfur con t ent of 0.0015 % by weight . This was done to reduce particle emissions in the exhaust. The use of ultra-lo w sulfur diesel f u el does not permit e xtens ion of engi ne o[...]

52 Maintenance and Service Supplem ental Fu el Enhanc ers Suppl eme ntal a dditiv es are not recomm ended beca use of a high risk of injection system pr oblems or engine damag e. There are many aftermark et products av ail able today which are intended to be added by the customer . They genera lly increase operatin g cost without prov iding benefi [...]

Maintenance and Service 53 Prohibite d Additive s The addition of gasolin e to diesel fuel will create a serious f ire hazard. Serious personal in jury can result. The follo wing additi ves are specifically NO T allo wed and must NO T be mixed in with the vehicle d iesel fuel: 앫 Gasoline — Adding gasoline to diesel fuel will reduce the cetane n[...]

54 Maintenance and Service Fuel Sto rage If fuel is s tored on site: 앫 K eep storage tank co vered to pre vent water en try . 앫 DO NO T use a tank made of ga lvan ized metal or an y galvanized piping for diesel oil storage. Diesel will react with the zinc, forming solids that can clog fuel filters and cause engine damage. 앫 Fuel stored for a [...]

Maintenance and Service 55 Fuel Filters A primary fuel filter can be located on the engine or r emote mounted on the frame rail. This filter consists of a filter cartridge, a water separation bowl and may ha ve a fuel heater b uilt in. The secondary fuel filter is located on the left hand side, below the engine electronic control u nit (EECU). The [...]

56 Maintenance and Service Chassis Moun ted Primary Fuel Filter (O ptional) Fo r priming the fuel s ystem, see “Priming the Fuel Sys tem” on page 7 1. Repl acing Fu el Filters When draining the fuel filters, collect the waste in a fuel-safe container . Always dis pose of fuel according to Fe deral or local re gulations. T ake the drained fuel a[...]

Maintenance and Service 57 Maintenance When draining t he fuel tank, c ollect the waste in a f u el safe container . T ake the drained fuel an d water to a recy cle or waste management center . Open the drain at the bo t tom of the fuel t ank approxi mately e very 50 000 k m (30,000 miles) o r 300 hours, to drain of f an y wate r and/or sedim ent. [...]

58 Maintenance and Service DO NO T add e xt ra oil additives. Additives s uch a s br eak-in oils , top oils, graph i tizers, an d fricti on-r educing liq uids ar e not necessary and ca n harm the engine . Oil Change Intervals The length of time an engine can operate be fore an oil change d epends on t he quality oil used, the type of fuel used, fue[...]

Maintenance and Service 59 D11F and D13F Oi l Filters (D1 3F shown, D11F similar) Synthetic Lubri cation Synthetic oils are of fered by some o il suppliers as an altern ative to the traditio nal, petroleum based oils for engines. These oils ma y be used in V olv o engines, provided they m eet the quality lev els specified on the pre vious pages , t[...]

60 Maintenance and Service V olvo T ru cks North America recommends the viscosities shown in the viscosity/temperature table for V olvo engines. Oil Additives Extra oil additives must ne ver be added to any engine oil used. Add itives suc h as br eak-in oil s, top oils, gra phitizers, and frict ion r educing liquids ar e not necessary and may even [...]

Maintenance and Service 61 All diesel engines are d es igned to consume some oil, so it is normal to add oil periodically . An engine used in hea v y-duty operation will consume more oil than one in n ormal operation. T o assist you in measuring yo ur oil us age please r efer to the Fuel and Oil Record on “Fuel and Oil Record” on page 120. Oil [...]

62 Maintenance and Service It is importan t to drain as much oil as possible. T ry to change oil immediately after dri ving, when the oil is war m . Always replace the oil filters when changin g oil. Oil Filters Change Hot oi l can cause s ever e burns. DO NO T allow hot oil to contact the skin . When changing oil, wear pr otectiv e gloves. V olvo-[...]

Maintenance and Service 63 ENGINE AIR FILTER Continued operation with the gauge showin g in the r ed may cause damage to the engin e. Opera t ing the engine with a da m a ged fil t er allo ws dust to pas s directly i nto the en gine, c ausi ng dam age. Rep lace damaged or clogged filters. The engine air filter is monitored by a pressure restriction[...]

64 Maintenance and Service USA22978.bk.book Page 64 Wednesday, July 9, 2008 9:09 AM[...]

Maintenance and Service 65 DIESEL PARTIC ULATE FILTERS (IF EQUIPPED) This vehi cle is equipped with a 2007 emission compliant engine and may be equipped with an exhaust aftertreatme nt system which includes a Diesel Particulate Filter (DPF). The DPF reduces soo t and particulate emissions into the atmospher e. V ehicles equipped with a DPF requ ire[...]

66 Maintenance and Service FAN AND AUXILIARY DRIVE BE LTS Hot engine. K eep yourself clear of all h ot engine parts and/o r fluids. A hot engine can cause serious b urns. All engine belts shou l d be checked at each s ervice point. Ins p ect for crack ed or frayed material. All belts hav e auto matic belt tensioners to keep the correct tension with[...]

Maintenance and Service 67 A dri ve belt routing label is located on the vehicle frame rail. Drive Belt Routing Label Drive Belt Routing Label Locati on USA22978.bk.book Page 67 Wednesday, July 9, 2008 9:09 AM[...]

68 Maintenance and Service TURBOCHARGER AND CHARGE AIR COOLER If oil leaks in ternally fro m the turbocharger to the engine in tak e , the oil acts as a fuel. W atch for excessiv e exhaus t smok e. DO NOT o p erate engine until problem is corrected. There is no w ay to regulate the engine speed if it runs on oil and it may ov er speed. Loss of cont[...]

Maintenance and Service 69 When using a pr essur e washer to clean the vehicle, do not dir ect the spray at electrical components in the eng ine compartment suc h as the alternator , starter and compr essor s. W ater spr ay fr om pr essur e washers ca n damage electrical components. The simplest method to clean the package is to u s e air pressure [...]

70 Maintenance and Service FUEL SYSTEM SERVICE Changing the Primary Fuel Fil t er T o a void potential f ire hazard, DO NO T service any part of the fuel system whil e smoking or in the presen ce of flames, sparks , or hot surfaces, or when working on an o pera ting engine. Failure to f ollow these precautions can result in f ire. T o guard ag ains[...]

Maintenance and Service 71 Priming the Fuel System The fuel system will need to be bled if: 앫 The ve hicle has run out of fuel. 앫 The en gine has not been r unnin g for an e xtended period of time. 앫 Service work h as been done on the fuel system, (tank , fuel lines, f ilters, v alves, etc.) for e x ample cleaning or replacing fu el filter el[...]

72 Maintenance and Service D11F and D13F Pr imer Pump (D 11F shown , D13F simi lar) 1. Unlo ck the hand pu mp by turning the ha ndle counterclockwise. 2. Prime t he syst em by movi ng the primer pum p in an up and down pumping m otion. Avoid pu t ting any side l oad on the pump or causing a bind ing co nditi on. 3. Lock t he hand primer pu mp by re[...]

Maintenance and Service 73 Water In Fuel Y ou can only drain the water in the fuel when there is a h ig h water le vel in the fuel f ilter housing, t he engine i s not r unning, the ve hicle is stationary and the parking brake is applied. When t he w ater in fuel indicator act i vates, the cluster displays the water in fuel icon and the message “[...]

74 Maintenance and Service If the temperatur e reaches 140 ° C (285 ° F ), stop the vehicle to let the temperature go down. See the v ehicle Op erator's Manual for i nfor mation on the optional transmiss ion temperature gauge. If the transmissi on oil temperatures ar e consistently high, change oil more often or install an oi l cooler . W it[...]

Maintenance and Service 75 Driveshaft If the driveshaft universal joints ar e not lubricated properly, they can be damaged to the point of t he drives haft separating from the vehicle. Driveshaft separation may caus e loss of control of the vehicle resulting in severe perso nal injury o r death. Periodi c inspection, lubrication, and main t enance [...]

76 Maintenance and Service STEERING AND BRAKES MAINTE NANCE Steering Sys t em Excessi ve play in th e steering syst em is checke d by turning the s teering wheel while th e engine is stopped. With the front wh eel s poi nting st raight ahead , turn the steering wheel until the front wheel starts moving. Then, turn the steering wheel the other way u[...]

Maintenance and Service 77 Power Ste ering Flui d Reservo ir The po w er steering fluid reservoir is filled with Automatic Transmission Fluid (A TF) De xron ® III for the p ower s teering system. Change fluid e very 240 000 km (150,000 miles). Change filter ev ery year or more often if necessary . If the fluid has darkened, it indicates that the p[...]

78 Maintenance and Service Brake System DO NO T use replacement parts anywhere in the brak e system unless it conforms exactly to original sp ecifications. A nonconforming part in your ve hicle's brak e system could cause a malf unction, leading to loss of control of the vehicle resulting in severe pers onal injury or death. DO NO T release th[...]

Maintenance and Service 79 Air Tanks Drain the air system ta nks at the r ecommended intervals. If condensation accumulates, moisture can enter the brak e system air valves, ca using corros ion or cloggi ng. The saf ety of th e brak e system could be compromised, leadi ng to an a ccident cau sing sev ere person al injur y or de ath. When draining t[...]

80 Maintenance and Service ELECTRIC AL SYSTEM MAINTEN ANCE Battery Care Battery posts, terminals and r elated accessories contain lead and lead compounds, chemicals known to the St ate of Ca lif ornia to cause cancer and reproductive harm. W ash hands aft er handling. Always wear eye pr otection when working ar ound batteries to pre vent the risk o[...]

Maintenance and Service 81 The electrolyte lev el o n maintenan ce free batteries cann o t be check ed. Periodically , the condition and the state-of-char ge of each battery shou ld be checked by a V olvo T ruck dealer . Maintenance free batteries DO NO T require any attentio n other than keeping them clean and f irmly clamped in place in their res[...]

82 Maintenance and Service TIRES, WHEEL S AND HUB MAINTENANCE Wheel Safety Information DO NO T attempt to repair wheels or tires unless you are trained an d equip ped to do so. Wheel an d tire assembli es cannot be w orked on without proper tools and equipment. F ailure to follow this may lead to serious pers onal in jury or deat h. F a ilure to pr[...]

Maintenance and Service 83 DO NO T inst all tires with a load ra ting that is less than s tated on the Certification Label in th e door frame. The tire could be uninten tionally ov erloaded, lead ing to an accident , causin g serious pers onal injur y or death. DO NO T use mismatched tires on the same axle. Always use the same type (radial or bias [...]

84 Maintenance and Service Wheel Nut Ti ghtening F a ilure to prope rly torque-tighten th e wheel nuts can result in the b reakage of wheel studs and the subsequent los s of wheels. This can lead t o loss of v ehicle cont rol and seri ous pers onal injury o r deat h. After the initial tightening, ret ightening must be made within the first 800 km ([...]

Maintenance and Service 85 Tire Inf lation and Wear DO NO T operate the vehicle with under -inflated tires. Always keep y our tires inflated to the manufactur er's r ecomm endation. Increas ed flexing in the tire sidewall produces heat. The heat can b uild to the po int of blowing the tire o u t causing an accident. Check tire pr essure when t[...]

86 Maintenance and Service Tire Hints Hints on How to Avoi d Unnecess ary Tire Wea r 앫 Maintain correct t ire pressure 앫 Check the tire pressur e when the tires are cold 앫 Check that v alve caps are not m i ssing 앫 K eep the wheels balanced 앫 T ire wear increases with speed 앫 Overload i ng not only decr eas es tir e life b ut also creat[...]

Maintenance and Service 87 Typical Wear Patterns Incorrect A ir Pressure A. Air pres sure too high gi ves rapid wear i n the middle. B. Air pr essur e too low g i ves rapi d shou lder we ar . Incorr ect Ca mber Incorrect camber giv es abnormal wear o n one half of the tire. USA22978.bk.book Page 87 Wednesday, July 9, 2008 9:09 AM[...]

88 Maintenance and Service Incorrec t Toe a nd Axle Alignmen t A. Incorrect toe-in B. Incorr ect toe-out C. Out-of-line axle D. Steering arm defect Dual Whee l Mountin g A. Excessi ve road camber , dif ferent types of tire, dif ferent circumference or of f-center loading gi ve fas ter wear on one tire. B. Air pres sure too lo w , mismatched rims fo[...]

Maintenance and Service 89 Incor rect Caster an d Imbalance A. Caster angle B. Imbala nce Also rapidly wears the mechanical pa rts o f ste erin g link age, ki ngp in and wheel bearing. Cuts in the Tire T read A. Cuts B. Flaking cuts C. Rubb er flaking Cuts are du e to poor roads, air p ressure too high or incorrect tire type. USA22978.bk.book Page [...]

90 Maintenance and Service Spot We ar Sudden brak ing, locking brak es or out-of-rou nd brake drums gi ve spot wear . Feathe red Edge s Normal occurren ce on non-dri ving wheel s on good ro ads and high mileage. USA22978.bk.book Page 90 Wednesday, July 9, 2008 9:09 AM[...]

Maintenance and Service 91 Cupping Cupping is a n ormal occurrence that depends on the tread pattern; the higher the load, the gr eat er the wear . USA22978.bk.book Page 91 Wednesday, July 9, 2008 9:09 AM[...]

92 Maintenance and Service Front Wheel Hubs F a ilure to keep w heel bearings properly adjusted and lubrica ted may result in accelerated tire w ear , poor hand ling and, in extreme cases, wheel separation from the hub or from the spindle resulting in los s of vehicle contr ol and ser ious persona l inj ury or death. The front wheel hubs can be fil[...]

Maintenance and Service 93 Unitized Front Hubs The non-tap ered axle hubs are seal ed with lubricant inside the hub and do not require lubri cation. Unitized Hubs, Non-T apered Axle End USA22978.bk.book Page 93 Wednesday, July 9, 2008 9:09 AM[...]

94 Maintenance and Service T aper ed Axle End USA22978.bk.book Page 94 Wednesday, July 9, 2008 9:09 AM[...]

Maintenance and Service 95 CHASSIS MAINTENANC E Springs This wor k is best performe d by a V olv o T ruck dealer or o ther servi ce outlet having the p roper equi pmen t. The spring pack age is fastened to the ax le beam with U-bolts. It is important that the U-bolt nuts are properl y tightened. The nuts may loosen up with time. Sev ere roads and s[...]

96 Maintenance and Service Spring Bushings When lubricating the sp rings, lift the ax le off of the floor , suspend the frame with axle stands and l o wer the axle. The spring b ushings are no w in the position where greas e can be added to the contact surf aces. If the spr ing bu s hings are greased witho ut t aking the lo ad of f, high wear and l[...]

Maintenance and Service 97 CAB MAINTENANCE Doors The door lo ck mechanism shou l d be greased annually using white greas e. Lubricate the doo r lock cylinder with liquid graph i te annually , or more often in climates with a lot of snow and sa lt on the road s . Coat the doo r stop arm with white grease annually . On wet and sa lted roads, road spr[...]

98 Maintenance and Service Hood The hood latch mechanism should be greas ed with white grease yearly . If the mechanism is hard to work or binds, the latch should be cleaned before greasing. Rust Protect ion The rust protection applied when th e cab was produced is adequate for normal use and serv i ce. If an e xtension of the cab ru st protection [...]

Maintenance and Service 99 Cab Air Filter Air going into the cab passes a filter located on the right, front side of the cab . Remov e the f i lter and check it e very 19 200 km (12,000 miles ). The filter should not be cleaned an d reused. Replace with a ne w filter as necessary . Change the filter more often if driving in dusty conditions. A clog[...]

100 Maintenance and Service DO NO T aim the water jet direc t ly at door and window seals o r door locks. If locks are filled w ith water , use compressed air to clean the water out and then apply liquid graphite. Be especially careful of leaving water in locks or around seals during freezing w eather . Apply a coat of wax re gularly . This will he[...]

Maintenance and Servi ce 101 Nev er use steel wool to clean chrome. Pieces of the steel wo ol break of f and can create rust st ains on the surf ace. Aluminum Unprotected aluminum surfaces will form an oxide layer if not maintained. This is especially important d uring the co ld season when roads are salted or in coastal areas where the salt level [...]

102 Maintenance and Service LUBRICATION Chassis Lubricati on Before work ing on or servic ing a vehi cle, set the parking brak es, place the transmissi on in neutral and chock the wheels. F ailur e to do so can result in unexpected vehicle mo vement and can cause seri ous per sonal inju ry or death. General lubrication inclu des lubricating all the[...]

Maintenance and Servi ce 103 Lubricati on Chart The numbers in t he lubrication ch art co rresp ond with the numbe red notes on “Lubrication Chart Notes” on page 104. Read these notes b efore selecting a lubricant. USA22978.bk.book Page 103 Wednesday, July 9, 2008 9:09 AM[...]

104 Maintenance and Service Lubricati on Chart Notes 1. Spring h anger : Use a lithium-based grease with specif ication API NLGI No. 2. When lubr icating the lef t and right sid es of the front springs, lift the axle of f of the floor , suspend the frame with axle stands and lower the axle. The spring bushings are no w in the positio n where grease[...]

Maintenance and Servi ce 105 4. Draglink and steering shaft: Use a lithium-based grease with specification API NLGI No. 2. 5. Kingpin, upper an d lower: Use a lithium-based grease with specification API NLGI No. 2. Always grease a V olvo front axle with the wheels on t he groun d. Non-V olvo axles are typically greased with the wheels on the ground[...]

106 Maintenance and Service Ensure that grease pu rges out of all four seals of the U-joints. 10. PTO/Hydraulic reservoir: If eq uipp ed, co nsult with th e PTO manufactur er for the latest recommendation. 11. T -Ride bogie bea m (48k-70k suspension ): If equipped, u s e a lithium-based grease wi th EP additi ves to specif icat ion API NLGI No. 2. [...]

Maintenance and Servi ce 107 18. A uto matic and manual tran smission: 앫 Automatic transmis sion: Use Dexron ® III automatic transmissio n fluid. See the manuf acturer's oper ator manu al for interv als and quantity . 앫 Manual transmissio n: Use a mineral or synthetic oil. Check oil level periodically . Le vel should be to the bottom of t[...]

108 Maintenance and Service OIL CAPACITY TABLES AND VISCOSITY CHARTS Use the information in the table below to determine the operating conditio n and usage applicable to your v ehicle. D11F and D13F Engine Oil and Filter Change Interval s Clutch Hydrauli c System Eaton Fuller Transmi ssion 9,10, 13, 15 and 18–speed Engin e Operati ng Cond ition M[...]

Maintenance and Servi ce 109 Meritor Si ngle RS23, 25, 26 and 30, Meritor Tandem RT40, 44 and 46 Select vi scosity f rom the table ab ove. T empe ratures refer to stab le ambi ent temperature r e adings. Ther e is no upper limit to these outside temperatur es, but the axle sump temper ature MUST NEVER EXCEED 120 ° C (25 0 ° F). For oil change int[...]

110 Maintenance and Service Eaton Single 230 80, 23105, 26105 an d 30105Eaton Tandem DS405, DD405, DDH44 and DS462 For oil change intervals, see the ma nufacturer's operato r's manual Capacity 23080 19 lite rs (20 quart s ) 23105 and 26105 26.5 li ters ( 28 quart s) DD404, front tandem DD404, rear tandem 14.5 liters (15 .5 quarts) 13 lite[...]

Service Check L ist 111 Steering Hyd r aulic Syste m Hubs SERVICE CHECK LIST Flui d type Automa tic T ransmission Fluid (A TF) Dexron ® lll Change i nterval Eve ry 240 000 km (150 ,000 mile s) or every 12 months Oil T ype T empera ture Motor oil AP I CD or CE, SAE 30, 15W4 0 or synthe tic Mini mum: -25 ° C (-15 ° F) Ma ximum: No limit Gear oil A[...]

112 Service Check List PREVE NTIVE MAINTENANCE Once you determ i ne the applicable o pera ting condition for y our v ehicle, use the information in the table below to perform pr e ventiv e maintenance. TYPE OF OPERA TION CHECK / CHANGE BAS I C (4 MONTHS) CHECK / CHANGE ANNU AL (12 MONTHS) ADDITIONAL SER VICE Check W arning and Control Lamps XX Chec[...]

Service Check L ist 113 Check Batteries -Dirt, Leakage, Attachment , Specific Gravity of Battery Acid, Fluid Lev el Conn ections and Battery Box XX Check Fuel T ank , Hoses, Pi pes V enting and M ounting XX Check Fuel W ater Separator for the Fuel system, Dra ining of Cond ensatio n. XX Check Tire W ear X X Chassis Lubrication X X Cab Lubric ation [...]

114 Service Check List Check Mo untin g for Front and Rear Axle XX Check Chassi s Frame and Crossmemb ers XX Check Rear Whee ls and Bearings XX Check Brake Lini ngs X X Check Brake Cylinders, Le vers and Forks XX Check Oil Le vel in Manua l T ransmi ssion (If Applicable) XX Check Oil in Retarder XX Check Oil Le vel in Po wer Steering XX Check Air C[...]

Service Charts 115 SERVICE CHARTS V alve Adjustme nt X REQUIRED: Once a year, e very 209 000 km (130,0 00 miles) or every 2,500 h ours, (whichever comes fi rs t ) Check Drive Belts X X Che c k R adiat or Fa n, Bearing T o lerance, Bolt Unions, Fan Cover and Fan Ring with Rubber Seal XX Check T urbo charger X X Check Disch ar ge Lines and Hoses XX T[...]

116 Service Charts SCHE DULED SER VICE S The v ehicle had a pre-deli very in spection before being deliv ered to you, the custom er . Re gular maintenance ins pections should b e continued. The maintenance program and lubricatio n intervals that are listed in this manual may not suit you r operation. Cont act your n earest V olvo T ruck d eal er , [...]

Service Charts 117 Schedu led Serv ice Date Pre ventiv e Maintenan ce (See local V olvo T ruck dealer for Service In f ormation in group 17, " Preventive Mainte nanc e Basic S ervice" an d group 17 , "Preventi ve Maintenance An nual Service”) Wo r k C o m p l e t e d Date Mile age USA22978.bk.book Page 117 Wednesday, July 9, 2008 9[...]

118 Service Charts REPAIR RECORD Keep track of repairs bein g made. This helps over the lifetime of the vehicle to spot trends that can be us ed to alter maintenance schedu l es, for e xample. Repair Record Date Mile age Wo r k Ord er o r In voi ce No. Dealer Notes 1/1/07 24 816 XXX XXX Basic Pre venti ve Mainte nance: oil, f ilter and lube chassis[...]

Service Charts 119 TIRE RECORD Ti re R e c or d Date Ty p e Front T y pe Rear Notes (Tire Pr es sure, T read Depths) 1/1/0 7 Lo w pro 22.5 Mich X2A Lo w pro 22.5 Mich XD A All tires with in 105 - 108 psi T read Dept h, Front 12/32, Rear 10 /32. USA22978.bk.book Page 119 Wednesday, July 9, 2008 9:09 AM[...]

120 Service Charts FUEL AND OIL RECORD K eeping track of the fuel an d oil consump tion giv es a record of what is no rmal for the v ehicle. This can be compared wi th other vehicles in the s ame service application to indicate what is no rmal fuel and oil consum ption for a certain application. Keep a reco rd of how mu ch fuel was filled b etween [...]

Litera ture 121 ENGINE DATA Consult your autho rized V olvo Truck dealer . LITERATURE Fill in th e blanks f or futur e re ference V ehicle Identificatio n Number (VIN) Engin e Model Eng ine Seri al Numb er Engin e Power Rating Primary F u el Filte r Par t Number Second ary Fuel F ilter Part Numbe r Oil Filter Part Number , Full Flo w Oil Filter Par[...]

122 Litera ture SERVICE ASSI STANCE AND MANUAL S Y our V olvo T ruck dealer is trained an d equipped to perfo rm expert service on your V olvo v ehicle. Y our dealer ha s direct access to V olvo T rucks North America for technical h el p, pa rts or service infor mati on. V olvo Action Service (V AS), prov i des on- cal l assistance. F or help, cont[...]

Index 123 A Air Dryer M aintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9 Air Filter , Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9 Air Filter , Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Air Tank Dr aining . . . . . [...]

124 Index Engine O verview, D11F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 , 40 Engine O verview, D13F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 , 40 Engine S hut-Down S ystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Engine S torage . . . . . . . . . . . . . . . . . . . . . . [...]

Index 125 N Noise Em issions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 O Oil Addit ives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Oil Change Intervals . . . [...]

126 Index T Tires, Whee ls and Hu bs Maintenan ce . . . . . . . . . . . . . . . . . . . . . . . .82 Transmissio n Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Turbocharg er and Charg e Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . .68 U U-bolts . . . . . . . . . . . . . . . . . . . . . . . . .[...]

T ruck Model & Serial Engine Model & Serial T ransmission Model & Serial Rear Axle Model & Serial Your T ruck Was Delivered By: If you need assistance on the road or if you need service repairs, contact the VAS support center . VAS is available 24 hours per day , 7 days per week at 1-800-528-6586 . Please report the specific nature [...]

V olvo T rucks North America P .O. Box 26115 Greensboro, NC 27402-6115 V olvo T rucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www .volv otrucks.volv o.com PV776-21012002 07.2008 © V olv o Group North America, Inc. 2008. All Rights Reserved.[...]