Volvo VN User manual

Service Manual
Trucks
Group 171–500
Pre-Delivery Inspection
VN, VHD
PV776-TSP147914

Foreword
The descriptions and service procedures contained in this manual are based on de-
signs and methods studies carried out up to April 2001.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary ser-
vice bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a refer-
ence to an S.R.T. (Standard Repair Time).
Service procedures which do not include an operation number in the title are for gen-
eral information and no reference is made to an S.R.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to
have the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could oc-
cur.
Volvo Trucks North America, Inc.
Greensboro, NC USA
Order number: PV776-TSP147914
Repl: This manual replaces Service Manual 171–500 “Pre-Delivery Inspection”, publication no. PV776–TSP142924 and
Supplement 171–500–01, “Axle Shaft Gaskets, Pre-Delivery,”publication no. PV776-TSP144734, of 8/2000.
© 2001 Volvo Trucks North America, Inc., Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced, stored in
retrieval system, or transmitted in any forms by any means, electronic, me-
chanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc..

Contents
General .................................................................................................... 3
Pre-DeliveryInspection ............................................................................ 3
Pre-Delivery Inspection ......................................................................... 5
1711–09–02–01 Pre-DeliveryInspection .............................................. 5
Cab Interior ....................................................................................... 5
Cab Exterior Including the Chassis .................................................. 8
Fluid Levels and Lubrication ........................................................... 12
Test Drive........................................................................................ 19
Pre-DeliveryInspection Form.............................................................. 22
Feedback
1

2

Group 17 General
General
Pre-Delivery Inspection
W1000076
The Pre-Delivery Service Manual is written for the purpose of assuring the customer
and Volvo Trucks North America, Inc. that the vehicle is checked and inspected before
actual delivery to the customer.
This manual together with the Operator’s Manual for the vehicle are a help to service
personnel and should be used with the Pre-Delivery Inspection Sheet at the end of this
information.
This is not a step-by-step procedures manual and, when necessary, other manuals will
be noted when reference is needed. Where the phrase “Check for proper operation”is
used, it is assumed that an experienced technician, with a working knowledge of the
vehicle and its basic operation, is performing the check. Technicians not familiar with
basic vehicle operation should receive adequate training to the point where an inspec-
tion of the vehicle can be carried out with an assurance that the judgement to pass an
item as being in good condition is made with certainty.
When using the “Pre-Delivery Inspection Form”page 22, note on the back of the form
under NOTES any defects found when doing the inspection.
3

4

Group 17 Service Procedures Pre-Delivery Inspection
Pre-Delivery Inspection
1711–09–02–01
Pre-Delivery Inspection
The “Pre-Delivery Inspection Form”page 22 should be
used when doing the Pre-Delivery Inspection. Fill in the
form and add a copy to the owner’s package.
Cab Interior
W9000144
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 personal in-
jury or death.
1Vehicle Literature
Check the vinyl envelope that is provided with the vehi-
cle to see that it contains the following information:
•Operator’s Manual for Vehicle
•Operator’s Manual, Maintenance and Engine
•Operator’s Manual, Vendor Engines or Transmis-
sions
•Dealer Directory
•Truck Warranty Certificate
•Product Report
•Publications Order Form
•Incomplete Vehicle Document
•Wheel Alignment Information
•Truck Order Bill Listing
•Weight Certificate
•Tire Warranty
Note: Other literature may be provided depending on the
configuration of the truck. Such literature includes, but is
not limited to:
•Engine Brakes
•Radio, etc.
5

Group 17 Service Procedures Pre-Delivery Inspection
W8000947
2Horn(s)
Sound the air horn (1) and electric horn (2) to ensure
proper operation.
Each horn should have a strong, clear tone.
W8000893
3Safety Belts, Sleeper Restraints
Check the safety belts for function and condition. Oper-
ate the belt latch and verify that it locks and unlocks
properly. Check belts for:
•Smooth rolling when rolling out and retracting.
•Check mounting bolt tightness and for any defects in
hardware.
W8000895
If the vehicle is a sleeper model, verify that the restraint
harness latches operate properly. Check condition of the
webbing.
6

Group 17 Service Procedures Pre-Delivery Inspection
W8002768
4Seats
Check both seats for proper function. Operate the
switches to verify function.
If seat has the heater option, turn on the switch and feel
for heat.
Note: The heater will only work at ambient temperatures
under 103 ± 5

F (40 ± 3

C).
W3000756
5Radio
Turn on the radio (if equipped) and verify that it operates
without distortion or static noise.
Check all functions of:
•Radio
•Tape deck
•CD player
Note: Use the same cassette and/or CD recording every
time to test the sound system.
W3000809
6Interior Lights
Operate the switches of all interior lights to verify func-
tion and that the bulbs light up:
•Ceiling light
•Bunk lights
•Door lights
•Luggage compartment lights
Note: The overhead light is operated by the door switch
in one position and will stay on in the other position.
7

Group 17 Service Procedures Pre-Delivery Inspection
Cab Exterior Including the Chassis
W1000061
7Cab
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 personal in-
jury or death.
Check all paint on the cab, hood and chassis. Note any
discrepancies.
W8001288
Check all chrome, for example grille, chrome acces-
sories, etc., for damage or discoloration.
W8000855
Check cab mounting and suspension. Check the ride
height for cab air suspension. For the proper operation
for checking the cab suspension, refer to service infor-
mation in group 81.
Measure from top of spring plates to top of cab suspen-
sion crossmember. Correct ride height is 6.850 ± 0.157
in. (174 ± 4 mm).
8

Group 17 Service Procedures Pre-Delivery Inspection
W8000897
8Hood Latch and Tilt
Check the hood latches for proper adjustment and oper-
ation.
Check operation of hood restraint cylinders. Inspect
splash shields. Raise and lower the hood to ensure
proper operation and make sure that the latches secure
the hood when closed.
W7000046
Gasket for aluminum hubs
W4002087
O-ring for steel hubs
9Drive Axle Shaft Gaskets
On vehicles where the axle shafts were removed for
transportation, check for cracks or tears in the gaskets or
O-rings. If any damage can be seen, replace gasket or
O-ring. Remove transport cover. Install new gasket (for
aluminum hub) or O-ring (for steel hub). Inspect gasket
or O-ring surface on the axle shaft to make sure it is
clean. Install axle shaft.
Fastener Torque Values, ft-lb (Nm)
Thread
Size (in.) Lock Nut
0.75-16 275 ± 25
(372 ± 34)
W4000895
10 Drive Axle Shaft Nuts
On vehicles where the axle shafts were removed for
transportation, check-tighten the drive axle shaft nuts to
the correct torque, as indicated.
9

Group 17 Service Procedures Pre-Delivery Inspection
W1000148
11 Fuel Tanks
Remove protective coating on polished tanks if tank is
exposed.
W7000774
Wheel Nut Torque Tightening Sequence
12 Wheel Nuts
All disc wheels for the VN or VHD-series have fasteners
that require a torque of 450 ft-lb (610 Nm). For dual
wheels, the following procedure must be used:
1 Loosen outer nuts.
2 Tighten inner nuts to a torque of 450 ft-lb (610 Nm).
3 Tighten outer nuts to a torque of 450 ft-lb (610 Nm).
For spoke wheels, check the manufacturer specifications.
W7000437
13 Tires
Check the tires for proper inflation and leak-test the
valve stems.
10

Group 17 Service Procedures Pre-Delivery Inspection
W3004392
14 Exterior Lights
Check headlights, marker lights, turn signals, stop, and
tail lights for proper operation.
Check headlight aim.
W2003594
Inserting stack pipe to stops
1 Stops
2 3 1/2 in. (38.1 mm)
W2003595
Aligning clamp
1 Correct
2 Incorrect
15 Exhaust Clamp
If the exhaust stack has been removed during towing,
the clamp must be retorqued after reinstallation of the
stack pipe. Check to be sure the top edge of the clamp
is flush with the top of the muffler. The clamp must cover
the slots.
Finish tightening nut to a torque of 32-37 ft-lb (43.5-50
Nm).
11

Group 17 Service Procedures Pre-Delivery Inspection
Fluid Levels and Lubrication
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 personal in-
jury or death.
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving parts or hot engine parts and/or
fluids. A hot engine and/or fluids can cause burns or
can permanently damage test equipment.
Note: Check fluid levels with the vehicle on level ground.
If the fluid level is low, add as necessary. If oil has to be
added, use only the same type of oil that is already in
the component. Also check for any leaks and note on
the back of the “Pre-Delivery Inspection Form”page 22.
W2002047
16 Engine
CAUTION
Do not mix synthetic oils with petroleum-based oils.
Mixing synthetic oils with petroleum-based oils can
cause component failure and/or component damage.
Check the engine oil level. The acceptable level is be-
tween the MIN and MAX marks on the dipstick. If the oil
level is above the top mark, oil should be removed from
the oil sump. Check for visible oil leaks.
W4000768
17 Transmission/Oil Cooler
CAUTION
Do not mix synthetic oils with petroleum-based oils.
Mixing synthetic oils with petroleum-based oils can
cause component failure and/or component damage.
Check the oil level in the transmission by removing the
fill/level plug in the side of the transmission housing or
check with the dipstick. The oil should be level with the
bottom of the fill/level plug hole or according to the mark-
ing on the dipstick. Check for visible oil leaks.
For Allison automatic transmission, refer to the Allison
Operator’s Manual for proper fluid level checking proce-
dures.
12

Group 17 Service Procedures Pre-Delivery Inspection
W0000233
18 Rear Axle(s)
CAUTION
Most rear differentials have a large screw and nut pro-
truding from the housing. The screw and nut hold the
thrust plate shoe against the ring gear and are not to
be confused with the fill/level plug.
CAUTION
Do not mix synthetic oils with petroleum-based oils.
Mixing synthetic oils with petroleum-based oils can
cause component failure and/or component damage.
Check the oil in the differential by removing the fill/level
plug in the housing. The oil should be level with the bot-
tom of the fill/level plug hole. Check for visible oil leaks.
19 Auxiliary/Transfer Case
Not offered for the VN or VHD series.
W6000877
20 Front Axle
Tighten the spring U-bolt nuts to a torque of 310 ft-lb
(420 Nm).
13

Group 17 Service Procedures Pre-Delivery Inspection
W7000438
21 Front Axle Hubs
CAUTION
Do not mix synthetic oils with petroleum-based oils.
Mixing synthetic oils with petroleum-based oils can
cause component failure and/or component damage.
For front axles equipped with oil lubricated wheel bear-
ings, check the fluid level in front axle hubs. Check for
visible leaks.
W6001428
22 Steering System
CAUTION
Do not mix synthetic oils with petroleum-based oils.
Mixing synthetic oils with petroleum-based oils can
cause component failure and/or component damage.
Check the fluid level in the power steering reservoir with
the engine off. The level should be at the full mark on
the dipstick. Check for visible leaks.
Note: Do not overfill the power steering reservoir or fill
with the engine running. For proper fluid type, refer to
decal affixed to the power steering reservoir.
On vehicles equipped with steering helper cylinder or
gear on the right side of the frame, check the compo-
nents for visible leaks.
23 Cab Tilt Pump
Not used for the VN or VHD-series.
14

Group 17 Service Procedures Pre-Delivery Inspection
W2001430
24 Cooling System
WARNING
Do not remove the coolant fill cap (or cap on the ex-
pansion tank) until coolant temperature is less than
120

F (50

C). Otherwise, scalding steam or fluid may
escape under pressure, which can cause serious in-
jury.
WARNING
Do not work near the fan with the engine running or
the ignition in the ON position. The engine fan can en-
gage at any time without warning. Anyone near the
fan when it turns on could be seriously injured.
Check to see that the coolant/anti-freeze in the radiator
is at the proper level. Pressure test the system and
check for leaks. For information, refer to service informa-
tion in group 26.
15

Group 17 Service Procedures Pre-Delivery Inspection
W4000749
25 Clutch Reservoir
CAUTION
Do not mix synthetic oils with petroleum-based oils.
Mixing synthetic oils with petroleum-based oils can
cause component failure and/or component damage.
Check fluid level in the clutch fluid reservoir. Add if nec-
essary.
26 Lubrication
Grease all points as indicated in the “Lubrication Chart”
page 17.
Note: When necessary, refer to the Preventive Mainte-
nance Service Manual for more information and
procedures.
16

Group 17 Service Procedures Pre-Delivery Inspection
Lubrication Chart
Spring hanger (2)
Note 8 Coolant level Note 1
Slack adjuster & brake
cam (4) Note 9 Steering assist cylinder. Note 18
Steering gear (1)
Note 10 Power steering fluid Note 2
Kingpin, upper & lower (4)
Note 11 Wheel bearings Note 3
Tierod (2)
Note 12 Engine oil & filter Note 4
Spring hanger (4)
Note 8
Clutch bearing and linkage. Note 15 Clutch cylinder fluid
Note 5
U-Joint (1)
Note 13 Automatic transmission. Note 16
Manual transmission
Note 6
U-Joint (1)
Note 13 Auxiliary axle(s) Note 17
U-Joint (1)
Note 13
Rear axle
Note 7
Slack adjuster & brake
Cam (4) Note 9
T-Ride bogie beam (2)
Note 14
Slack adjuster & brake
Cam (4) Note 9 Rear axle Note 7
W1000146
Grease Coolant
Hub Oil Aut. Transm. Fluid
Engine Oil Man. Transm. Oil
Hydraulic Oil Rear Axle Oil
There are notes for each
type of lubrication on the
next page. Read the notes
before selecting a lubricant.
Steering Fluid Brake Fluid
17

Group 17 Service Procedures Pre-Delivery Inspection
Lubrication Chart Notes
CAUTION
Do not mix synthetic oils with petroleum-based oils.
Mixing synthetic oils with petroleum-based oils can
cause component failure and/or component damage.
1Add if necessary. Only use pre-mixed clean water
and antifreeze in a 50/50 mix.
Add only the same type antifreeze, that is: extended
life or standard.
2Check the fluid in the reservoir with the dipstick.
Add if necessary.
3Change the oil (or grease) only in connection with
work on the hub or if dirt is found in the lubrication.
4Change the oil according to the schedule in TSI
Service Bulletin 175–001.
5Check that the fluid is at the correct level. If needed,
add fluid.
6Level should be to the bottom of the inspection hole.
See TSI 175–001 for correct oil.
7Check the oil level in the rear axles. The oil should
be level with the inspection hole. Add if necessary.
See TSI 175–001 for correct oil.
8Use a lithium based grease with specification API
NLGI No. 2. When lubricating the springs, lift the
axle off of the floor, suspend the frame with axle
stands and lower the axle. The spring bushings are
now in the position where grease can be added to
the contact surfaces.
9Use a lithium based grease with specification API
NLGI No. 2. Use liberally in the slack adjuster. Make
sure the grease purges through the seal on the
brake cam.
Note: If the brake cam seal does not purge, make
sure the inner seal does not purge into the brake
drum and onto the brake linings.
Note: Low maintenance brake options, such as Mer-
itor LX500 brakes are frequently specified. If vehicle
is so equipped, follow manufacturer’s procedures,
lubrication type, and service intervals carefully.
10 Use a lithium based grease with specification API
NLGI No. 2. Only use a hand operated grease gun.
The high pressure from an air operated grease gun
will damage the seal.
11 Use a lithium based grease with specification API
NLGI No. 2.
Note: Always grease a Volvo front axle with the
wheels on the ground.
Note: To grease non-Volvo axles, they are typically
greased with the wheels on the ground. Consult with
the axle manufacturer for the latest recommendation.
12 Use a lithium based grease with specification API
NLGI No. 2.
Note: Volvo axles may use a greased-for-life tierod.
No provisions for adding grease are available.
13 Use a lithium based grease with EP additives to
specification API NLGI No. 2.
Note: Make absolutely sure that grease purges out
of all four seals of the U-joint.
14 Use a lithium based grease with EP additives to
specification API NLGI No. 2. Make sure the grease
purges out of both the outer and inner seals. If nec-
essary, adjust the lubrication schedule to include
greasing the bogie bearing as often as daily, in
applications where the bogie runs in corrosive con-
ditions or is submerged in water.
15 Use a lithium based grease with EP additives to
specification API NLGI No. 2. Do not over-grease the
throwout bearing as grease may get into the clutch.
16 See the manufacturer’s operator’s manual for inter-
vals and quantity.
17 If equipped with auxiliary lift axles, grease and lubri-
cate according to notes 3, 9, 11 and 12.
18 Use a lithium based grease with EP additives to
specification API NLGI No. 2 to grease both ball
joints.
18