Volvo Trucks VAH 2016 Instructions for use

SSeerrvviiccee IInnffoorrmmaattiioonn
Trucks
Group17
Preventive Maintenance
VAH, VHD, VN
89245095

Foreword
Order number: PV776-89245095
©2016 Volvo Group North America, Inc., Greensboro, NC USA
The descriptions and service procedures contained in this manual are based on designs and techni-
cal studies carried out through March 2016.
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 deemed to
have a significant bearing on this manual, an updated version of this manual 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 reference to an V.S.
T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for general information
and no reference is made to an V.S.T.
Each section of this manual contains specific safety information and warnings which must be re-
viewed before performing any procedure. If a printed copy of a procedure is made, be sure to also
make a printed copy of the safety information and warnings that relate to that procedure. The follow-
ing 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 occur.
Volvo Trucks North America, a division of Volvo Group North America,
Inc.
Greensboro, NC USA
USA75784

General..........................................................................................................................................1
General..........................................................................................................................................1
Preventive Maintenance, General....................................................................................................1
Section List..................................................................................................................................2
Maintenance Coverage..................................................................................................................3
Program Structure.........................................................................................................................3
Advantages..................................................................................................................................4
Maintenance Form ........................................................................................................................4
Maintenance Records....................................................................................................................4
Maintenance Preparation ...............................................................................................................5
Preventive Maintenance Inspection Bay ...........................................................................................5
Location ......................................................................................................................................5
Equipment ...................................................................................................................................5
Reception....................................................................................................................................5
Inspection....................................................................................................................................6
Other Inspection ...........................................................................................................................6
Safety Advice...............................................................................................................................7
Special Tools and Special Equipment...............................................................................................8
Special Tools................................................................................................................................8
Other Special Equipment ...............................................................................................................9
Lighting System, Special Tools...................................................................................................... 11
Lubrication General..........................................................................................................................1
Lubrication Chart ..........................................................................................................................1
Preventive Maintenance Inspection Checklist...................................................................................1
Preventive Maintenance Inspection Checklist...................................................................................1
Preventive Maintenance Checklist...................................................................................................1
Preventive Maintenance..................................................................................................................1
Premium Maintenance Routine Service ............................................................................................1
Checks in Cab..............................................................................................................................1
1. Check Clearance in Clutch Mechanical Function ............................................................................1
2. Check Transmission Pneumatic and Mechanical Control System......................................................3
3. Function Check of Headlamps and External Lamps ........................................................................3
4. Check Rear View Mirrors and Reflectors .......................................................................................3
5. Function Check Wipers and Washer.............................................................................................4
6. Check Differential Locks .............................................................................................................4
7. Check Gear Shift and Clutch Pedal ..............................................................................................4
8. Check Parking Brake .................................................................................................................5
9. Check Air Pressure Regulator Disconnection and Connection Pressure.............................................5
10. Check for Diagnostic Trouble Codes (DTCs) Displayed on Dash .....................................................6
11. Check After Start for Leaks........................................................................................................6
Oil and Fluid Level Check...............................................................................................................7
12. Perform Cab Lubrication ...........................................................................................................7
13. Change Engine Oil and Filters ...................................................................................................8
14. Check Oil Level in Transmission.................................................................................................9
15. Check Oil Level in PTO, Power Takeoff ..................................................................................... 11
16. Check Oil Level in Transfer Case ............................................................................................. 11
17. Check Oil Level in Front Drive Axle........................................................................................... 12
18. Check Oil Level in Rear Drive Axle ........................................................................................... 13
19. Check Oil Level in Power Steering............................................................................................ 14
20. Check Oil Level in Hubs for Oil Lubricated Wheel Bearings .......................................................... 15
21. Check Fluid Level in Clutch Fluid Reservoir ............................................................................... 16
22. Check Coolant Freeze Protection and Coolant Level ................................................................... 16
23. Fill Windshield Wiper and Headlamp Wiper Reservoirs................................................................ 17
Engine Compartment................................................................................................................... 18

24. Check Air Intake and Air Deflector ............................................................................................ 18
25. Check Alternator Mounting...................................................................................................... 18
26. Check Electrical Connections and Cables for Alternator, Starter Motor, and Intake Air Heater (IAH) .... 18
27. Check Drive Belts .................................................................................................................. 19
28. Check Engine Mounting.......................................................................................................... 20
29. Check Radiator Mounting........................................................................................................ 20
30. Check Radiator Fan, Bearing Tolerance, Bolt Unions, Fan Cover and Fan Ring with Rubber Seal ...... 20
31. Check Intercooler, Hoses, Pipes and Air Flow ............................................................................ 21
32. Check Radiator, Hoses, Pipes and Air Flow ............................................................................... 21
33. Check Charged Air Cooler (CAC), Hoses and Air Flow ................................................................ 22
34. Check Fuel Lines on Engine .................................................................................................... 23
35. Check A/C Compressor Mounting ............................................................................................ 23
36. Check Compressed Air Lines and Hoses................................................................................... 23
37. Check Power Steering Pump, Oil Lines and Steering Gear........................................................... 23
38. Check Clutch Hydraulic and Pneumatic Control System............................................................... 23
39. Check Air Filter Replacement Date (Ventilation System) .............................................................. 24
External Checks ......................................................................................................................... 25
40. Check Cab, Hood, Doors, Step Panels and Cab Suspension........................................................ 25
41. Drain Water from Fuel/Water Separator for the Fuel System and Change Filter................................ 26
42. Check Exhaust for Leakage..................................................................................................... 28
43. Check Batteries — Load Test, Leakage, Attachment, Clean and Protect (when necessary) Connections
and Battery Box Holddowns.......................................................................................................... 30
44. Check Fuel Tank and Ventilation Filters..................................................................................... 31
45. Check Front Shock Absorbers, Springs and U-Bolts.................................................................... 32
46. Check Front Wheel Bearings ................................................................................................... 33
47. Check Front Wheels............................................................................................................... 34
48. Check Steering Linkage.......................................................................................................... 35
49. Check Steering Knuckle Bearing.............................................................................................. 36
50. Check Air Pressure and Tire Wear............................................................................................ 37
Checks Beneath the Vehicle ......................................................................................................... 39
51. Check Front and Rear Axle Mounting........................................................................................ 39
52. Check Bearing Play for Pinion and Input Shaft to Rear Drive Axle.................................................. 39
53. Check Ventilation for Transmission, Transfer Case, and Power Takeoff (PTO)................................. 39
54. Check Mounting of Transmission, Transfer Case, and Power Takeoff (PTO) Including Lines .............. 40
55. Check Transmission Oil Cooler Mounting .................................................................................. 41
56. Check Retarder Mounting and Lines ......................................................................................... 41
57. Check Drive Shaft, Universal Joints, Sliding Joints and Support Bearings ....................................... 41
58. Check Clutch Adjustment........................................................................................................ 42
59. Check Lift Axle ...................................................................................................................... 42
60. Check Rear Drive Axle Ventilation, Rear Springs, U-Bolts and Rear Shock Absorbers ...................... 43
61. Check Seals for Speedometer Sensor....................................................................................... 43
62. Check Rear Wheels ............................................................................................................... 44
63. Check Load Sensing Valve...................................................................................................... 45
64. Check Air Bellow, Level Sensors and Level Valves for Air Suspension ........................................... 45
65. Check Chassis Frame and Crossmembers ................................................................................ 45
66. Check Air Dryer ..................................................................................................................... 46
67. Check Brake Circuit for Leaks.................................................................................................. 46
68. Check Brake Linings and Wheel Seals for Leaks ........................................................................ 48
69. Check Brake Cylinders, Levers, and Forks................................................................................. 48
70. Check Brake Disc and Brake Calipers....................................................................................... 49
71. Check Stroke Length on Slack Adjusters, Brake Levers and Brake Drums ...................................... 52
72. Check Brake Chambers and Mounting Brackets ......................................................................... 52
73. Check Central Lubrication System............................................................................................ 52
74. Perform Chassis Lubrication.................................................................................................... 53
75. VOLVO Blade Air Suspension (VBAS) Maintenance.................................................................... 64
Additional Time Based Maintenance .............................................................................................. 65

Group 17 Preventive Maintenance, General
General
Preventive Maintenance, General
W1000183
This manual describes inspection and lubrication requirements during the preventive mainte-
nance services of VOLVO Trucks North America. The purpose for doing the preventive mainte-
nance is to ensure that the vehicle is safe and road worthy over its full lifetime.
The driver is taking part in the continuous preventive maintenance program by completing the re-
quired 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.
Preventive Maintenance is a planned vehicle maintenance program that provides an orderly ser-
ies of servicing and inspection procedures. A well applied maintenance program realizes the in-
vestment 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 as-
sure the designed life expectancy of the vehicle and its individual components.
1

Group 17 Section List
Section List
“Maintenance Preparation”, page 5
“Safety Advice”, page 7
“Special Tools and Special Equipment”, page 8
“Lubrication Chart”, page 1
“Preventive Maintenance Checklist”, page 1
“Additional Time Based Maintenance”, page 65
2

Group 17 Maintenance Coverage
Maintenance Coverage
There is no firm maintenance program that will apply to all operations. A basic maintenance program is not difficult 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 program in this service manual covers all types of VOLVO vehicles with medium to high mileage and sometimes
high loads.
Use this established maintenance program as a base to tailor an individual maintenance program for customers that have re-
quirements that are outside of the scope of this program.
To establish an individual program, look at information sources that are usually available, such as:
•Driver's repair or complaint reports.
•Unusual parts usage.
•Repetitive failures or problems found in inspection.
•Unscheduled maintenance or repairs.
•Road failures.
Program Structure
This maintenance program has been based on the progress in vehicle technology and increases in oil quality to simplify the
maintenance.
For simplified scheduling, the program has tied maintenance to logical time or mileage limits that make it easy to anticipate
needed servicing.
See the engine types for recommended oil change intervals. The intervals do not cover all applications. In on/off highway driv-
ing, severe off-highway, continuous stop-and-go city driving and extremely high mileages, the oil change interval needs to be
customized for the best protection and economy. Change all oil filters at each oil change.
Synthetic oils do not allow further extension of oil drain intervals. It is the contamination rate, i.e., soot, and the depletion of addi-
tives, rather than base oil quality that determines the useful engine oil life and therefore the oil change intervals.
Note: North American engines meeting the emissions requirements are designed with exhaust aftertreatment systems requiring
a new engine oil quality. This has lead VOLVO to require an oil that meets VDS-4 and/or EO-O Premium Plus quality standards
for VOLVO engines. VDS-4 and EO-O Premium Plus are both based on the newly developed API CJ-4 engine oil specification,
but have additional performance requirements essential to adequately protect the VOLVO engines at the drain intervals speci-
fied. All oils listed in this bulletin also meet API CJ-4. Earlier engines also work better with the above mentioned oils, but are not
required.
For further information concerning maintenance scheduling, see service information in Function Group 1, Oil and Filters, VOLVO
Components and any appropriate vendor literature.
3

Group 17 Advantages
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 relations.
•Less possibility of accidents due to defective equipment.
•Fewer driver complaints.
Regardless of the planning and the details of the maintenance 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 inspection”; 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 inspection forms. Forms are created for different users but all with the same
references to this document. When the inspection point is carried out, check the box if the item is OK. If further work, such as ad-
justment, 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 adjustment need to be shown to the customer and scheduled for repair.
There are many time — and/or mileage-based — service items that are not listed on the form, they include:
•VOLVO Engine Valve Adjustment
•Engine Coolant
•Fan Hub
•Clutch Hydraulic Fluid (US Only)
•Air Dryers
•Eaton Fuller and Meritor Transmissions
•VOLVO Transmissions
Maintenance Records
It is important to use the inspection form together with other reports to come up with the best maintenance program for a specific
application. Use driver's reports, complaints, parts usage, repetitive failures, previous repair orders, road failures, etc. to build a
maintenance picture of the customer operation.
Records should be collected over the lifetime of the vehicle to form a permanent vehicle record file. The vehicle file should be
used to customize the operational maintenance 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 responsibility 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 service.
Note: The included Annual Service checklist is an uncon-
trolled copy. The document may be updated without notice.
4

Group 17 Maintenance Preparation
Maintenance Preparation
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 available, 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 assigned to that bay and not be shared with the rest of the shop. The floor
equipment should have floor space 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 in-
stead of having to use a helper, makes inspection easier and faster.
Reception
When the customer drops off the vehicle, the service receptionist starts the paperwork and prepares the forms needed for the
preventive maintenance. Ask the customer 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 problems?
As the vehicle is approached, check for signs of leakage, general appearance, body damage, etc. Walk around the vehicle. Note
on the preventive maintenance inspection form if any leaks or problems are found.
5

Group 17 Inspection
Inspection
Inspection is carried out depending on the application and operation of the vehicle. This inspection is designed to open up com-
ponents for inspection or using test equipment to record performance.
All inspection points are to be carried out as verification of function or condition. Any defects are noted on the inspection form for
later correction, if so ordered by the vehicle owner.
Note: The included preventive maintenance service checklist is an original copy. The document can be updated without notice.
Note: The standard repair time for performing the Preventive Maintenance Inspection includes the engine oil and filter
change, and chassis lubrication. Additional time for other repairs and/or adjustments are not included in the Preventive
Maintenance Inspection.
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 time. They should be scheduled as an adjustment or repair job carried out at the same time as their respective pre-
ventive maintenance, and are listed in this document as reminders only.
6