Volvo VHD Manuel de service

Service ManualTrucksGroup 177–500Preventive MaintenanceBasic ServiceVN,VHDPV776-TSP151476

8

Group 170Every:Three YearsCaterpillar: Engine Valves and In-jector PreloadEngine valve lash adjustment is checked and, if neces-sary, adjusted every t

Group 170Additional Mileage Based MaintenanceEvery:80,000 km (50,000 miles)Eaton Fuller and Meritor Transmis-sionsRegular oil change intervals when pe

Group 170Every:190,000 km (120,000 miles)Detroit Diesel: Engine Valve Clear-ance and Injector HeightCheck valve clearance and injector height. Adjust

FeedbackOne of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing,

Volvo Trucks North America, Inc.P.O. Box 26115, Greensboro, NC 27402-6115Volvo Trucks Canada, Ltd.6490 Vipond Drive, Mississauga, Ontario L5T 1W8http:

Group 177 SpecificationsSpecificationsEngineGeneralFor further information concerning component specifica-tions see service information in Group 1, “Oil

Group 177 SpecificationsVOLVO ENGINESNote: It is not recommended to mix synthetic oils withpetroleum based oils.For further information concerning comp

Group 177 SpecificationsDETROIT DIESEL ENGINESFor further information concerning component specifica-tions see service information in Group 1, “Oil and

Group 177 SpecificationsTransmissionIncludes Volvo, Eaton Fuller, Meritor, and Allison HD TransmissionsFor further information concerning component spe

Group 177 SpecificationsRear AxleIncludes Volvo, Arvin Meritor, and Eaton Dana Rear AxlesFor further information concerning component specifications see

Group 177 ToolsToolsSpecial Tools and Special EquipmentThe following special tools are recommended for use in the preventive maintenance in-spection.

Group 177 ToolsSpecial Tools (Continued)J-44302A/C Schrader Valve Core Removal ToolJ-443338Oil Dipstick for A/C CompressorJ-22610Drive Shaft Boot Camp

Group 177 ToolsSpecial Tools (Continued)PT 5900Chip Vacuum9998142Charge Air Cooler Pressure TesterJ-38641-BDiesel Fuel HydrometerJ-44544Ride Height Ga

Group 177 ToolsOther Special EquipmentJ-42397-ACoolant Pressure Test Adapter1089953Bulb Removal ToolJ-23600-BBelt Tension GaugeJ-38460-ADigital Inclin

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

Group 177 ToolsOther Special Equipment (Continued)9998691Oil Filter Nipple Installer Kit3947553, 3949521, 3946522, 3949523Terminal and Shim KitsJ-4470

Group 177 ToolsVCADS Pro ToolsThe following hardware is used to operate VCADS Pro. The tools can be ordered fromVolvo Trucks North America; please ref

Group 177 ToolsLighting System, Special ToolsThe tools listed below are used to complete maintenance on the Lighting System forVolvo Trucks. They may

Group 177 ToolsPreventive Maintenance Inspection BayLocationPreventive Maintenance is logically carried out at thesame time as lubrication of the vehi

22

Group 177 Design and FunctionDesign and FunctionClutchGeneralFor further information concerning component specifica-tions see service information in Gr

Group 177 Design and FunctionOther Clutch Slave CylinderA slave cylinder for any non-Volvo clutch has a wear in-dicator. When the indicator is out of

Group 177 Design and FunctionPower Take-offVolvo PTOFor further information concerning component specifica-tions see service information in Group 1, “O

Group 177 Design and FunctionBrakesBrake Cams and Slack AdjustersFor further information concerning component specifica-tions see service information i

Group 177 Design and FunctionSteering SystemSteering Linkage and KnucklesFor further information concerning component specifica-tions see service infor

ContentsGeneral ... 3Preventive Maintenance, General

Group 177 Design and FunctionSteering SystemFor further information concerning component specifica-tions see service information in Group 1, “Oil and F

Group 177 Design and FunctionChassisSprings and SuspensionNote: For further information concerning componentspecifications see service information in G

Group 177 Design and FunctionT-Ride Equalizer BeamNote: For further information concerning componentspecifications see service information in Group 1,

Group 170 Preventive MaintenancePreventive MaintenanceBasic ServiceIncluding Lubrication and Oil ChangeDate: Model: Reg. No.:Time: Vehicle Identificati

Group 170 Preventive MaintenanceEngine Compartment Checks36 Check Alternator Mounting and Electrical Connec-tions37 Check Drive Belts38 Check Radiator

Group 170 Preventive MaintenanceComments33

Group 170 Preventive MaintenanceReceptionW1000068When the customer drops off the vehicle, the service re-ception starts the paperwork and prepares the

Group 170 Preventive MaintenanceLubricationMake sure that grease fittings are cleaned off before fill-ing grease. Dirt on the fitting that is not cleaned

Group 170 Preventive Maintenance1Chassis LubricationNote: For VN vehicles only.Front Axle Steering KnucklesNote: For further information concerning th

Group 170 Preventive MaintenanceSteering LinkageNote: Greasable drag links are also available as an op-tion.1 Lubricate the Steering shaft and drag li

2

Group 170 Preventive MaintenanceSlack AdjustersNote: For further information refer to literature in Func-tion Group 5.There is one grease fitting per s

Group 170 Preventive MaintenanceClutch Bearing and Cross ShaftThe Volvo Clutch Release Bearing is sealed for life anddoes not need lubrication. Howeve

Group 170 Preventive MaintenanceFifth WheelNote: For further information refer to Function Group 9.Lubricate the plate pivot points and slide mechanis

Group 170 Preventive Maintenance2Cab LubricationLubricate Door Locks1 Grease door locks with white lithium grease asneeded.2 Clean excess grease off o

Group 170 Preventive MaintenanceA Oil PlugB Oil Filter1 Regulator Valve2 Bypass Valve for Oil3 Overflow Valve for Oil Filters (By-pass)4 Reducing Valve

Group 170 Preventive MaintenanceD12 Oil FiltersD7 Oil Filters1 Full-flow Filter2 Bypass FilterOil FiltersBefore working on a vehicle, set the parking b

Group 170 Preventive Maintenance4Check Oil Level In Manual TransmissionFor further information concerning component specifica-tions see service informa

Group 170 Preventive Maintenance5Check Oil Level in Automatic TransmissionBefore working on a vehicle, set the parking brakes,place the transmission i

Group 170 Preventive MaintenanceCold Check:Note: The fluid level rises as its temperature rises. Donot fill above the Cold Run band if the transmission

Group 170 Preventive MaintenanceHot Check:Note: The fluid must be hot to insure an accurate check.The fluid level rises as the temperature increases.1 O

Group 177 GeneralGeneralPreventive Maintenance, GeneralIntroductionThis manual describes inspection and lubrication re-quirements during the Basic Ser

Group 170 Preventive Maintenance6Check Oil Level in PTO (Power Take-Off)Note: For further information refer to Function Group 4.For further informatio

Group 170 Preventive Maintenance7Check Oil Level in RetarderFor further information concerning component specifica-tions see service information in Gro

Group 170 Preventive Maintenance1 Level/Fill Plug2 Drain Plug9Check Oil Level in Front Drive AxleNote: For further information refer to Function Group

Group 170 Preventive Maintenance1 Level/Fill Plug2 Drain Plug10Check Oil Level in Rear Drive AxleNote: For further information refer to Function Group

Group 170 Preventive Maintenance12Check Oil Level in Power SteeringNote: For further information refer to Function Group 6.For further information con

Group 170 Preventive Maintenance15Check Oil Level in Clutch Fluid ReservoirNote: For further information refer to Function Group 4.For further informa

Group 170 Preventive Maintenance18Check Air DryerAir DryersFor further information refer to Function Group 5.For further information concerning compon

Group 170 Preventive MaintenanceCab19Check Warning and Control LampsFor further information refer to Function Group 8.For further information concerni

Group 170 Preventive Maintenance20Check for Fault Codes in the Vehicle Elec-tronic Control UnitThe instruments and engine control units, are alwaysinc

Group 170 Preventive MaintenanceEngine ECU21Check for Fault Codes in the Engine Elec-tronic Control UnitUse Service Information in Function Group 23 a

Group 177 GeneralProgram StructureThis maintenance program has been based on theprogress in vehicle technology and increases in oil qual-ity to simpli

Group 170 Preventive Maintenance23Check for Fault Codes in TransmissionNote: Use Service Information in Function Group 4 as areference.To complete the

Group 170 Preventive Maintenance25Check Retarder ControlEnsure that the control’s steps are well-defined and thatthe control stops in the set position.

Group 170 Preventive Maintenance27Check Gear Shift and Clutch PedalTo perform a service check on the Gear Shift and ClutchPedal complete the following

Group 170 Preventive MaintenanceExternal Checks28Function Check of External LampsTo perform a function check of the External Lamps per-form the follow

Group 170 Preventive Maintenance30Function Check of Wipers and WashersCheck the wiper arm tension and condition of the wiperblades.31Check Battery Mou

Group 170 Preventive Maintenance32Check Fuel Tank, Hoses, Pipes andMounting StrapsTo complete a service check of the fuel tank, hoses,pipes and mounti

Group 170 Preventive Maintenance34Check Water Separator for Fuel SystemFor further information refer to Function Group 2.Note: If the filter is not bei

Group 170 Preventive Maintenance35Check Tire Wear and Wheel AlignmentTire WearFor further information refer to Function Group 7.1 Examine each tire tr

Group 170 Preventive MaintenanceTotal Vehicle AlignmentRear Tandem AlignmentWheel AlignmentCheck Total Wheel Alignment. For further information re-fer

Group 170 Preventive MaintenanceVehicle Thrust AngleThrustMeasure and compare thrust for both the left and rightside of the vehicle. Acceptable differ

Group 177 GeneralOther InspectionThere are additional service points that are carried out atspecific mileage or time intervals. These are not part ofth

Group 170 Preventive MaintenanceEngine Compartment Checks36Check Alternator Mounting and ElectricalConnectionsFor further information refer to Functio

Group 170 Preventive Maintenance38Check Radiator Fan, Fan Shroud and FanRing with Rubber SealFor further information refer to literature in FunctionGr

Group 170 Preventive Maintenance39Check Radiator, Hoses and PipesNote: For further information refer to literature in Func-tion Group 2.WARNINGDo not

Group 170 Preventive Maintenance41Check Fuel Pipes and LinesNote: For further information refer to literature in Func-tion Group 2.To complete a check

Group 170 Preventive Maintenance43Check Intercooler Pipes and HosesNote: For further information refer to literature in Func-tion Group 2.Note: This c

Group 170 Preventive MaintenanceCab Climate Control UnitRecovery/Recharge Unit Area45Check A/C Hoses, Fittings, Switches, andWiresNote: For further in

Group 170 Preventive MaintenanceFront Suspension, Steering System Checks46Check Gaiters/Plastic Covers and clear-ance for Ball JointsNote: For further

Group 170 Preventive Maintenance48Check Steering Shaft Joint, Hoses anPipes for Power SteeringNote: For further information refer to literature in Fun

Group 170 Preventive MaintenanceChecks Beneath the Vehicle49Check Sealing on Front and Rear DriveAxleNote: For further information refer to literature

Group 170 Preventive Maintenance51Check Gearbox, Transfer Case, andPower Take-Off Mounting and SealingNote: For further information refer to literatur

Group 177 GeneralNoise EmissionsVolvo Trucks North America, Inc. warrants to the firstperson who purchases this vehicle for purposes otherthan resale a

Group 170 Preventive Maintenance53Check Retarder SealingTo perform a check of the Retarder Sealing complete thefollowing:•Check the Retarder Sealing f

Group 170 Preventive Maintenance54Check Drive Shaft, Universal Joints, Slid-ing Joints and Support BearingsNote: For further information refer to lite

Group 170 Preventive Maintenance55Check Sealing of Rear Axle and Hub Re-duction GearNote: For further information refer to literature in Func-tion Gro

Group 170 Preventive Maintenance57Check Exhaust Pipe, Silencer, or Particu-later FilterNote: For further information refer to literature in Func-tion

Group 170 Preventive Maintenance59Check Central Lubrication SystemNot applicable to VN/VHD vehicles.60Check Air Suspension and Air SpringsNote: For fu

Group 170 Preventive Maintenance61Check Rear Wheel Bearing ClearanceNote: For further information refer to literature in Func-tion Group 7.To perform

Group 170 Preventive Maintenance63Check Brake LiningsNote: For further information refer to literature in Func-tion Group 5.To perform a check of the

Group 170 Preventive Maintenance65Check Brake Disc and CalipersNote: For further information refer to literature in Func-tion Group 5.To perform a che

Group 170 Preventive MaintenanceTest Driving67Check After StartCheck Clutch OperationNote: For further information refer to literature in Func-tion Gr

Group 170 Preventive MaintenanceCheck Instruments and GaugesNote: For further information refer to literature in Func-tion Group 3.Check all instrumen

Group 177 GeneralSafety AdviceNever operate a diesel engine in an area where hy-drocarbon vapors (gasoline for example) are presentor are suspected to

Group 170 Preventive MaintenanceCheck HornsNote: For further information refer to literature in Func-tion Group 8.Sound both the air horn (1) and the

Group 170 Preventive MaintenanceCheck ABS SystemNote: For further information refer to literature in Func-tion Group 5.To do the brake test safely, en

Group 170 Preventive MaintenanceCheck Engine Controls and PerformanceNote: For further information refer to literature in Func-tion Group 3.Check engi

Group 170 Preventive MaintenanceCheck Transmission OperationNote: For further information refer to literature in Func-tion Group 4.Check the transmiss

Group 170 Preventive MaintenanceCheck Heater and Air ConditioningNote: For further information refer to literature in Func-tion Group 8.Check function

Group 170 Preventive Maintenance69Check After Test DrivingCheck Pneumatic SwitchesNote: For further information refer to literature in Func-tion Group

Group 170 Preventive MaintenanceEngine Low IdleNote: For further information refer to literature in Func-tion Group 3.Record the engine low idle speed

Group 170 Preventive MaintenanceCheck Compressor LoadingNote: For further information refer to literature in Func-tion Group 5.Raise the air pressure

Group 170 Preventive Maintenance70FinishDrive Vehicle; Check FluidsDrive the vehicle around the block to settle the oil and toverify any points that w

Group 170Additional Time Based MaintenanceEvery:YearVolvo EngineAdjust valves on the VE D7C and the D12 engine every12 months, regardless of mileage.