Volvo VHD 2001 User manual

Operator's Manual
Maintenance and Engine
VHD

Foreword
This manual contains information concerning the safe operation of your
vehicle. It is extremely important that this information is read and un-
derstood before the vehicle is operated. This manual also contains a
considerable amount of information concerning the vehicle, such as ve-
hicle identification, Preventive Maintenance recommendations and a log
for your service records. Please keep this in the vehicle at all times. In-
formation from other component manufacturers is supplied in separate
manuals in the Owner’s Package.
NOTE! It is important that this manual stays with the vehicle when it
is sold. Important safety information must be passed on to the new cus-
tomer. The service information contained in this manual gives the
owner important information about maintaining the vehicle but is not
intended as a substitute for the Preventive Maintenance Service Manual
and must not be regarded as such.
The National Highway Traffic Safety Administration (NHTSA) and
Volvo Trucks North America, Inc. should be informed immediately if
you believe that the vehicle has a defect that could cause a crash, in-
jury or death.
Contact NHTSA by calling the Auto Safety Hotline at 1 (800) 424–
9393 (or 366–0123 in the Washington, DC area) or by writing to:
NHTSA, U.S. Department of Transportation, Washington, DC 20590.
Volvo Trucks North America, Inc.
Greensboro, NC USA
Order number: PV776-TSP20154789
© 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, mechanical, photocopying, recording or otherwise, without
the prior written permission of Volvo Trucks North America, Inc..

Contents
General Information ............................. 1
Information For the Owner ................... 1
Safety Information ................................. 3
Proper Maintenance Procedure ............. 3
Injury Prevention ................................... 6
Engine Damage Prevention ................. 15
Electric System Damage Prevention .. 17
Reporting Safety Defects .................... 19
General Engine Design Information .20
Engine Overview D7 ........................... 20
Engine Overview, D12 ........................ 22
Typical Engine Compartment
Overview ............................................. 24
Engine Features ................................... 26
VECTRO II Parameter Values, D7 .... 27
VECTRO II Parameter Values, D12 .. 28
Engine Variants, D7 ............................ 29
Engine Variants, D12 .......................... 30
Engine Data ......................................... 31
Engine Storage ..................................... 32
Engine Storage .................................... 32
Cooling System ..................................... 34
General Coolant Information .............. 34
Water Specification ............................. 40
Additives .............................................. 41
Antifreeze ............................................ 42
Fuel System .......................................... 50
Fuel Safety Reminders ........................ 50
Diesel Fuel Specification .................... 51
Fuel Additives ..................................... 55
Alternative Fuels ................................. 58
Oil System ............................................. 59
Engine Oil ........................................... 59
Oil Sampling ....................................... 70
Severe Service Schedule for
VHD-Series ........................................... 74
General and Check-Chart ................... 74
Maintenance Categories ...................... 78
Heavy-Duty Service Schedule for
VHD-Series ........................................... 84
General and Check-Chart ................... 84
Maintenance Categories ...................... 89
Maintenance ......................................... 95
Engine Maintenance ............................ 95
Flushing Cooling System, D7 .......... 121
Flushing Cooling System, D12 ........ 124
Turbo and Charge Air Cooler ........... 126
Replacing Fuel Filters ....................... 128
Fuel System Service ......................... 129
Transmission and Rear Axle Main-
tenance ............................................... 139
Steering and Brakes Maintenance .... 143
Electrical System Maintenance ......... 149
Tires, Wheels and Hub Maintenance 151
Chassis Maintenance ......................... 155
Cab Maintenance ............................... 157
Lubrication, VHD ............................. 162
Viscosity and Capacity Tables .......... 166
Literature ............................................ 172
Service Assistance and Manuals ...... 172
Service Charts .................................... 174
Scheduled Services ........................... 174
Repair Record ................................... 177
Tire Record ........................................ 183
Fuel and Oil Record ......................... 194
Index .................................................... 207

Warning Label Information
IMPORTANT
Before driving this vehicle, be certain that you have read and that
you fully understand each and every step of the driving and han-
dling information in this Operator’s Manual. Be certain that you
fully understand and follow all safety warnings.
IT IS IMPORTANT THAT THE FOLLOW-
ING INFORMATION CONCERNING
LABELS IS READ, UNDERSTOOD AND
ALWAYS FOLLOWED.
The following types of labels are used
throughout this manual:
NOTE! A note defines an operating proce-
dure, practice, condition, etc., which is
essential to the proper operation of the ve-
hicle.
CAUTION
A caution label directs the operator’s
attention to unsafe practices where per-
sonal injury is not likely but property
damage could occur. The caution label is
in black type on a white background
with a black border.
WARNING
A warning label directs the operator’s
attention to unsafe practices which could
result in personal injury or severe dam-
age to the vehicle. The warning label is
in black type on a gray background
with a black border.
A danger label directs the operator’s at-
tention to unsafe practices which could
result in serious personal injury or death.
The caution label is in white type on a
black background with a black border.

General Information 1
Information For the Owner
If there are questions on the maintenance
and performance of your vehicle, please
discuss them with your Volvo Truck dealer.
Your authorized dealer is required to have
trained mechanics, special tools and spare
parts to fully service your vehicle. If neces-
sary, your dealer will contact Volvo Trucks
North America or other manufacturer for
any assistance.
In addition to this Maintenance Manual,
there may be additional instruc-
tion/operator’s manuals supplied by
component manufacturers. These manuals
are placed in the Owner’s Package and
placed in the cab. Be sure to read all the
manuals thoroughly before operating the
vehicle.
Also, various safety labels may be placed
on components by the component manufac-
turer. Be sure to read and follow these
labels to prevent damage to the vehicle,
personal injury or even death.
Information in this manual refers to Volvo
components and Volvo drivetrain. Informa-
tion concerning non-Volvo engines and/or
drivetrains can be obtained by contacting
the respective manufacturer.
Establish a Preventive Maintenance Pro-
gram with the help of your local Volvo
Truck dealer. A Preventive Maintenance
Program makes it possible to maximize the
amount of time your vehicle is up and run-
ning, resulting in longer component life.
This makes for a safer vehicle by reducing
any mechanical failures due to poor mainte-
nance practices.
NOTE! Federal law requires manufacturers
to notify owners of its products in the event
of a Federal Motor Vehicle Safety Standard
or if a safety related defect is discovered. If
you are not the original owner of this vehi-
cle, please notify us about the change in
ownership at the address below or through
an authorized Volvo Truck dealer. This is
the only way we will be able to contact
you if necessary.
Volvo Trucks North America, Inc.
P. O. Box 26115
Greensboro, NC 27402–6115
United States of America

2 General Information
Do Not Remove this manual from the ve-
hicle. It contains important operational and
safety information that is needed by all
drivers and owners of this vehicle.
This Maintenance Manual covers all Volvo
vehicles manufactured by Volvo Trucks
North America, Inc., including the whole
chassis and all Volvo manufactured compo-
nents. Specific maintenance information on
vendor components, manufactured by, for
example: Cummins, Detroit Diesel, Fuller,
Meritor, etc., see the respective manufac-
turer’s service and maintenance literature.
This manual, together with manuals for
specific components, for example, Volvo
engine, Cummins engine, Eaton transmis-
sion, etc., contain important information to
be able to operate this vehicle safely. They
contain advice and instructions which will
enable you to get the operating economy
and performance that you expect from this
quality vehicle.
All information, illustrations and specifica-
tions contained in this manual are based
upon the latest product information avail-
able at the time of publication. If any
questions arise concerning the current sta-
tus of Federal or state laws, the appropriate
Federal or state agency should be contacted.
Volvo Trucks North America, Inc. reserves
the right to make changes at any time or to
change specifications or design without no-
tice and without incurring obligation.

Safety Information 3
Proper Maintenance Procedure
During Maintenance
Whenever performing maintenance or re-
pair, attach a DO NOT OPERATE or
similar warning label or sign to the ignition
key or prominently displayed on the instru-
ment panel.
Do not allow unauthorized personnel on,
around or in the vehicle when mainte-
nance or repair is being performed.
WARNING
Do not attempt to repair or service this
vehicle without having sufficient train-
ing, correct service literature and the
proper tools. Failure to follow this could
lead to personal injury or making your
vehicle unsafe.
WARNING
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects
and other reproductive harm.
•When operating the engine in an en-
closed area, vent the exhaust to the
outside.
Exhaust gases contain carbon monoxide.
Always run the engine outdoors or use a
properly vented exhaust hose. Prolonged
or excessive exposure may cause serious
illness or death.
•Before servicing your vehicle, apply
the parking brakes and adequately
chock the wheels in order to prevent
unintended vehicle movement. If the
service procedure requires the parking
brakes to be released — recheck to en-
sure that the wheels are adequately
chocked to prevent all forward and/or
rearward movement.
•Do not use combustible substances in
or around the engine either during re-
pair or maintenance or when running
the engine.
Never operate the engine in an area
where hydrocarbon vapors (gasoline, for
example) are present or are suspected to
be present. Hydrocarbon vapors can en-
ter the air intake and overspeed the
engine, causing severe engine damage
and/or an explosion and fire. Serious
personal injury or death could occur.
•Do not wear loose clothing or jewelry
that can catch or get snagged by parts
or moving components on the engine.
Also wear all protective equipment re-
quired by the job conditions, such as
protective glasses, hearing protection,
etc.
•Make certain that all protective covers
and guards are in place and secured.
•Never put maintenance fluids into
glass containers since glass containers
can break.

4 Safety Information
•Report all problems in a timely man-
ner before they threaten the safety of
operating the vehicle.
•Do not work on the engine while it is
running.
•Tag the vehicle with the DO NOT
OPERATE sign. Make sure other pro-
tective locks and covers are in their
proper place.
•Disconnect the batteries whenever
performing any repairs or before ser-
vicing the electrical system.
•DO NOT use high amperage elec-
tronic starting devices for
jump-starting the engine. Rely on con-
ventional battery charging for charging
the batteries or jump-start with the
help of a start battery.
•DO NOT attempt repairs you do not
understand or have the proper tools for.
•When starting an engine after repairs
have been made to the fuel or injection
system, prepare equipment for shutting
off the engine intake air and/or fuel
supply (to stop the engine), in case
there is an overspeed on start-up.
•Start the engine only from the driver
seat. Never operate the starter motor
across the starter terminals or the bat-
teries as this could by-pass the engine
neutral-start system as well as causing
damage to the electrical or electronic
systems.
Never try to operate or work on this
vehicle while under the influence of al-
cohol. Your reflexes can be affected by
even a small amount of alcohol. Drink-
ing and operating this vehicle can lead
to an accident, causing serious personal
injury or death.

Safety Information 5
Compressed Air and Water
Compressed air can cause personal in-
jury. When using compressed air for
cleaning, wear a protective face shield,
protective clothing and protective shoes.
Pressurized water could cause particles
and/or hot water to be sprayed in your
direction and cause personal injury. The
maximum air pressure must be below
30 psi (200 kPa) for cleaning purposes.
Asbestos Information
NOTE! The Volvo engine and replacement
parts for it shipped from the factory are as-
bestos free. Volvo recommends the use of
only genuine Volvo spare parts.
Never use any parts that contain or are
thought to contain asbestos. Exposure to as-
bestos fibers can create serious health risks,
including death.
Fluid Penetration
Always use a piece of paper or
cardboard when checking for a leak. Es-
caping fluid under high pressure, even a
pin-hole sized leak, can penetrate body
tissue, causing serious injury or death. If
fluid is injected into your skin, immedi-
ate treatment must be administered by a
doctor familiar with this type of injury.

6 Safety Information
Injury Prevention
Burn Prevention
Engine Parts
WARNING
Hot engine. Keep yourself clear of all
hot engine parts and/or fluids. A hot en-
gine and/or fluid can cause serious burns.
Do not touch any part of the engine while
it is hot. Allow the engine to cool before
any repair or maintenance is performed on
the engine.
WARNING
Do not raise the engine hood or cab if
you see or hear steam or coolant escap-
ing from the engine compartment. Wait
until steam or coolant cannot be seen or
heard any longer before raising the hood
or cab.
Do not remove the coolant fill cap if the
coolant in the surge tank is boiling.
Also, do not remove the cap while the
engine and radiator are still hot. Scalding
fluid and steam may be blown out under
pressure if the cap is taken off too soon.
Relieve all pressure in air, oil, fuel or cool-
ing systems before any lines, fittings or
related items are disconnected or removed.
W0001525

Safety Information 7
Coolant
To prevent personal injury, do not climb up
on the engine to remove the filler cap. Use
a suitable, properly positioned ladder to
reach up to the cap. At normal operating
temperature, the engine coolant is very hot
and under pressure. If pressure is relieved
rapidly in a hot cooling system, the hot
coolant can turn into steam. Any contact
with hot coolant or steam can cause severe
burns. The radiator and all heating system
and radiator lines and hoses contain hot
coolant.
WARNING
Coolant may be combustible. Coolant
leaked or spilled onto hot surfaces or
electrical components can cause a fire.
Clean up coolant spills immediately.
Verify coolant level only by the markings
on the expansion tank. Open the filler cap
only after the engine has been stopped and
cooled down. Remove the filler cap slowly
to relieve pressure.
W0001527

8 Safety Information
Oils
WARNING
Hot engine. Keep yourself clear of all
hot engine parts and/or fluids. A hot en-
gine and/or fluid can cause serious burns.
Hot oil can cause severe burns. Do not al-
low hot oil to contact the skin. When
changing oil, wear protective gloves.
Batteries
WARNING
Always wear eye protection when work-
ing around batteries to prevent the risk
of injury due to contact with sulfuric
acid or an explosion.
WARNING
Battery posts, terminals and related
accessories contain lead and lead com-
pounds, chemicals known to the State of
California to cause cancer and reproduc-
tive harm. Wash hands after handling.
Battery electrolyte contains acid and can
cause injury. Avoid contact with the skin
and eyes. Wash hands after touching batter-
ies and connectors. Use of gloves is
recommended. Always wear protective
glasses when working with batteries.

Safety Information 9
Fire or Explosion Prevention
The diesel engine will operate on any
fuel which enters the cylinder, whether it
is from the injectors or from the air in-
take system. Therefore, if any solvent is
used to flush out the air cleaner element,
the engine may overspeed during
start-up. Engine damage and severe
injury and/or death from burns or explo-
sion can occur.
The engine should not be operated in an
area where combustible gases are suspected
to be in the air. These could be drawn into
the engine through the engine air intake
system and could cause the engine to over-
speed with possible serious damage to the
engine and bodily injury or property
damage.
W0001526
Excessive heat may cause the pressur-
ized components of the air conditioned
system to explode. Never weld, solder,
steam clean or use a gas torch near any
part of the air conditioning system. Se-
vere injury or death may occur from an
explosion.
Do not pressure or leak test R134a refriger-
ant for air conditioning or servicing
equipment using compressed air. Some
mixtures of air and R134a refrigerant have
been shown to be combustible at elevated
pressures. These mixtures, if ignited, can
cause injury or property damage. Consult
the R134a Material Safety Data Sheet
(MSDS) for additional information.

10 Safety Information
Do not service any part of the fuel sys-
tem while smoking or in the presence of
flames, sparks or hot surfaces. Failure to
follow these precautions can result in
fire, which can cause serious injury or
death.
All fuels, most lubricants and some coolant
mixtures are flammable. Diesel fuel is
flammable. Gasoline is flammable. The
mixture of diesel and gasoline fumes is ex-
tremely explosive. Do not smoke while
refueling or when in a refueling area.
WARNING
Do not store fuel containers in the vehi-
cle. They may leak, explode and cause
or feed a fire. Empty or full, they
present a hazard that may lead to burns
in the event of a fire.
Keep all fuels and lubricants stored in
properly marked containers and away from
all unauthorized personnel. Store oily rags
or other flammable material in a protective
container, in a safe place. Remove all
flammable material such as fuel, oil and
other substances before they accumulate on
the engine. Do not expose the engine to
flames, driving over burning ground, etc., if
at all possible. Do not weld or flame cut on
or around pipes or tubes that contain
flammable fluids.
W0001527

Safety Information 11
Exhaust heat shields may be installed to
protect oil or fuel carrying lines and pipes
from hot exhaust parts. To protect from pipe
or seal failure, install heat shields correctly.
Provide adequate and proper waste oil dis-
posal. Always dispose of waste liquids
according to Federal and local regulations.
Oil and fuel filters should be properly in-
stalled and housing covers tightened to the
proper torque when being changed.
Starting Aids
Do not use ether or similar starting aids
in a Volvo or any other engine with start
help. The Volvo engine is equipped with
a preheater. Introduction of ether or
other combustible material in the intake
manifold could cause a fire or explosion,
resulting in severe property damage, se-
vere personal injury or death.
DO NOT use ether or other combustible
starting aids on engines that have a heater
element or other heating devices installed
in the intake manifold for heating intake air
at cold-starts.
W0001484
Fire Extinguisher
Anytime work is being done to the fuel
system or any other area where flammable
substances are being used, have a fire extin-
guisher available and know how to use it.
Inspect and have it serviced as recom-
mended on its instruction label.

12 Safety Information
Respiratory Hazard Prevention
Exhaust gases contain carbon monoxide.
Always run the engine outdoors or use a
properly vented exhaust hose. Prolonged
or excessive exposure may cause serious
illness or death.
WARNING
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects
and other reproductive harm.
Always work in a well ventilated space if
the engine needs to be running and use a
hose to route the exhaust to the outside.
W0001523
Poisonous Substances
Coolant is toxic; risk of poisoning. Do
not drink coolant. Use proper hand pro-
tection when handling. Keep coolant out
of reach of children and animals. Failure
to follow these precautions can cause se-
rious illness or death.
Cooling system supplemental additive con-
tains alkali. To prevent personal injury,
avoid contact with the skin and eyes. DO
NOT drink coolant of any concentration.

Safety Information 13
Crushing or Cutting Prevention
Before working on a vehicle, set the
parking brakes, place the transmission in
neutral and block the wheels. Failure to
do so can result in unexpected vehicle
movement and can cause serious per-
sonal injury or death.
Do not work near the fan with the en-
gine running or the ignition in the ON
position. The engine fan can engage at
any time without warning. Anyone near
the fan when it turns on could be seri-
ously injured.
Support equipment and components prop-
erly when working beneath them. Never
attempt adjustments while the engine is
running unless otherwise specified for the
service procedure. To help prevent an acci-
dent caused by moving parts, work
carefully around them. Guards, covers and
shields should be in place whenever main-
tenance is not being performed. Keep
objects away from moving fan blades. They
will throw or cut any object or tool that
falls or is pushed into them.
Inspect the fan blade assembly before ser-
vice for cracks or loose mounting before
starting the engine. Never stand along side
a rotating fan assembly, particularly at high
fan speeds.
W0001524

14 Safety Information
Wear protective glasses when striking ob-
jects to avoid injury to your eyes. Chips or
other debris can fly off objects that are
struck. Make sure no one can be injured by
flying debris before striking any object.
W0001528
Climbing Up and Down
Always have three limbs (one foot and
two hands or two feet and one hand) in
contact with the vehicle at all times
when entering or exiting the cab or the
area behind the cab. Failure to follow
this warning can result in serious per-
sonal injury or death.
DO NOT climb up on or jump off from the
engine or stand on components that cannot
support your weight. Use an adequate lad-
der or scaffolding, suitably situated. Do not
use top of engine or cowling ledge as
foothold when reaching on top of cab.
Clean steps, handholds and areas of the ve-
hicle you will be working on or around.
Refer to the Operator’s Manual for proper
entry and exit procedures.
Always use a three-point stance (two
hands — one foot or one hand — two
feet) whenever climbing up or down.

Safety Information 15
Engine Damage Prevention
Before Starting the Engine
Before working on a vehicle, set the
parking brakes, place the transmission in
neutral and block the wheels. Failure to
do so can result in unexpected vehicle
movement and can cause serious per-
sonal injury or death.
Inspect engine for potential hazards. Make
sure all protective guards and covers are
properly installed if an engine needs to be
started to make adjustments or checks. To
help prevent an accident by moving parts,
work carefully around them.
DO NOT disable or bypass automatic
alarm/shutoff circuits. They are provided to
prevent personal injury and engine damage.
The diesel engine will operate on any
fuel which enters the cylinder, whether it
is from the injectors or from the air in-
take system. Therefore, if any solvent is
used to flush out the air cleaner element,
the engine may overspeed during
start-up. Engine damage and severe
injury and/or death from burns or explo-
sion can occur.
Make provisions for shutting off the engine
intake air or fuel supply to stop the engine
if there is an overspeed on start-up after
performing repair or maintenance on it.
Always consult the proper Volvo Service
Manual before any repair is attempted.

16 Safety Information
Engine Starting
DO NOT start the engine or move any of
the controls or disengage the parking brake
if the warning tag “DO NOT OPERATE” is
attached to the ignition key or located on
the dash. Check with the person who at-
tached the tag before starting.
Make sure no one is working on or close to
the engine or components driven by the en-
gine before starting it. Always make an
inspection of the engine before and after
starting.
Diesel engine exhaust contains products of
combustion which may be harmful to your
health. Always start and operate the engine
in a well-ventilated area, and if in an en-
closed area, vent the exhaust to the outside.
Start the engine only from the driver seat in
the cab. Never start the engine by shorting
across the starter motor terminals or batter-
ies to start the engine as this could bypass
the engine neutral-start system as well as
damage the electrical and electronic sys-
tem. Always start the engine according to
the required engine starting procedure de-
scribed in this operator’s manual to prevent
major engine component damage and per-
sonal injury.
Starting Aids
DO NOT use ether or other combustible
starting aids on engines that have a heater
element or other heating devices installed
in the intake manifold for heating intake air
at cold-starts. Introduction of ether or simi-
lar starting aids could cause a fire or
explosion resulting in severe property dam-
age, serious personal injury or death.
W0001484