Volvo VN User manual

Service Manual
Trucks
Group 182–500
Rustproofing Cab
VN, VHD
PV776-TSP144735

Foreword
The descriptions and service procedures contained in this manual are based on de-
signs and methods studies carried out up to August 2000.
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-TSP144735
© 2000 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
Rustproofing Information ....................................................................... 3
Specifications ......................................................................................... 5
Cavity Wax ............................................................................................. 5
Tools ........................................................................................................ 7
Rustproofing, Special Equipment .......................................................... 7
Design and Function ............................................................................. 9
Rustproofing Cab ................................................................................... 9
Service Procedures ............................................................................. 11
General WorkProcedures ................................................................... 11
Rust Prevention, Inspection ................................................................. 11
Rust Prevention, Retreatment (Complete Cab) .................................. 15
Rust Prevention, Retreatment (Complete Cab) .................................. 20
Feedback
Operation Numbers
1

2

Group 18 Rustproofing General
General
Rustproofing Information
W1000098
This manual covers information and procedures for rust-
proofing all types of cabs for the VN and VHD series. All
information needed for carrying out the work procedure
is contained in this manual.
The VN and VHD cabs rust warranty is in effect for 8
years or 1 610 000 km (1 000 000 miles) from the date
of purchase, whichever comes first. The warranty covers
rust-through from the inside out.
If rust is found during the warranty period, that does not
automatically mean that the affected area should be re-
paired. Contact the Volvo Warranty Department for more
information in each case. If a repair is done to correct
rust within the warranty period, the warranty continues to
its normal expiration if the repaired area is primed,
painted and treated with cavity wax according to good
work practices.
If a repair is made to the cab structure or the body pan-
els, the warranty is voided for that part of the cab. The
bodyshop that repaired the cab will warrant the repair
area to cover any future rust and/or structural problems
stemming from the repair.
When repairing the cab, always reapply primer, topcoat
and rust preventive wax on inside metal surfaces.
For carrying out the rust protective procedure, see:
•“Specifications”page 5
•“Tools”page 7
•“Design and Function”page 9
•“Rust Prevention, Inspection”page 11
•“Rust Prevention, Retreatment (Complete Cab)”
page 15, Daycab
•“Rust Prevention, Retreatment (Complete Cab)”
page 20, Sleeper Cab
3

4

Group 18 Rustproofing Specifications
Specifications
Cavity Wax
Type ............................................................................................................................................ Solventborne, semi-firm
Drying time ............................................................................................................................................... 24 h (fully dry)
Application temperature ..................................................................................................................... above 18

C (70

F)
Minimum wax coating thickness ......................................................................................................... 10
 m (0.0004 in.)
Heat resistance ................................................................................................................................ max. 100

C (212

F)
Tested lifetime ....................................................................................................................................... 1 000 h saltspray
Effect on paint finish ................................................................................................................................................ None
Thinner1/cleaner ............................................................................................................................................. White spirit
1) The listed manufacturers recommend that the wax is used at the viscosity as shipped. If unused wax is stored in a
closed container, the viscosity should not not need any adjustment. Wax with too low viscosity may cause too much
runoff and not give the proper coverage.
WARNING
Use a breathing mask and safety goggles during ap-
plication. Prevent prolonged or repeated inhalation of
vapor or spray mist. If cavity wax vapors are inhaled
and giving respiratory problems, see a doctor immedi-
ately. Use gloves to avoid skin contact. Wash
contaminated skin with soap and water. There are no
OSHA regulations for this product. Always order a
Material Safety Data Sheet when ordering wax.
5

6

Group 18 Rustproofing Tools
Tools
Rustproofing, Special Equipment
The equipment can be ordered from Air Power, Inc., P.O.Box 773, 520 Apperson Dr.,
Salem, VA 24153, Ph. (800) 848–1011.
W0001585
VRS-100 Cavity Wax Spray Kit
(takes a 5 gallon pail)
Cavity Wax
Order in 5 gallon pails from:
Wax, type 74–104S
Continental Products, Co.
1150 East 222 Street
Euclid, OH 44110
Ph. (216) 531–0710
Fx. (216) 289–1745
Order aerosol spray cans (for spot treatment) from:
Wax, order number 16018Z
Eastwood Co.
P.O.Box 3014
Malvern, PA 19355
Ph. (800) 345–1178
Fx. (610) 644–0560
www.eastwoodco.com
Order in 5 gallon pails from:
Wax, type Dinitrol®NCP 3623
EFTEC North America
31601 Research Park Drive
Madison Heights, MI 48071
Ph. (248) 585–8299
Fx. (248) 585–3799
7

8

Group 18 Rustproofing Design and Function
Design and Function
Rustproofing Cab
General
W1000098
In production, the cab is treated against rust with several
coats of primer and paint over a surface preparation pro-
cedure. This gives very good initial rust coverage. In
some areas, rust protection is added on top of the paint
to increase the rust protection (see shaded areas in the
illustration).
Before installation of upholstery, the cab is treated with
cavity wax at the factory (see areas shaded in the illus-
tration). This way, the wax can be precisely applied and
allowed to dry before the cab is dressed. Reapplication
of cavity wax has to be done with as little remove and in-
stallation work as possible.
The areas shaded in the illustration can be retreated, ex-
cept for the side inner rail which is located above the
luggage hatch. All other areas are accessible from exist-
ing cut-outs in the cab panels and profiles. Some
components are removed to uncover the cut-outs.
9

Group 18 Rustproofing Design and Function
Application
Rust is iron oxide (Fe2O3). Rust forms in the presence of
water (H2O) on an unprotected iron surface or where the
primer and top coat is damaged. Cavity wax works on
the principle that if air and moisture cannot reach the
material surface, there cannot be any oxidation of the
material. The liquid wax dries to a semisoft coating that
will slowly dry out. Depending on the manufacturer and
product, the drying period is typically between three to
five years.
The rustprotection applied when the cab was produced,
is adequate for normal use and service. If an extention
of the cab rustprotection is desired or if the vehicle is
used in a severe application, it is recommended that
cavity wax is re-applied every 3rd year.
The wax should flow easily when applied but not so easy
that it runs off without forming a good coat. Wax consis-
tency can be adjusted with mineral spirit if too thick. It
should flow and spray easily. Retreatment or new appli-
cation should be to specification. However, since it is
hard to measure the thickness of the coat, apply enough
to cover the surface but not so much that it starts to run.
Run-off does not harm the finished result, however, it is
wasted material.
W1000113
Application is typically done with an air gun and a flexi-
ble wand. The wand should have a 360

spray nozzle.
The wax is applied by inserting the flexible wand into a
profile and operating the air gun while slowly pulling the
wand out. Before application of the cavity wax, test the
spray pattern and coverage on a piece of cardboard. For
complete coverage, note the speed at which the wand is
moved. Try to simulate the same or slower application
speed when performing the application procedures. This
is especially important when treating areas (such as the
bottom rails) that can not be visually monitored during
the application.
W1000099
Before reapplication, the surface must be clean and dry.
If there are areas of rust, remove the rust and apply
primer before the wax is applied. Use Sherwin Williams
wash primer JBP 980 and allow it to dry thoroughly. Ap-
ply Sherwin Williams repair primer P6A47 and allow to
dry thoroughly.
The cab and wax should have a temperature of 18

C
(70

F) or above to get the right penetration into joints
and corners. If the surface must be cleaned before appli-
cation of wax, use water and let dry before applying the
wax.
In applications where rustprotection must be used in ar-
eas that are subject to abrasion (like wheel spray), there
are heavier rustprotection waxes available that are made
for exterior application.
10

Group 18 Rustproofing Service Procedures
Service Procedures
General Work Procedures
PERSONAL INJURY HAZARD! 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 injury or death.
WARNING
Use a breathing mask and safety goggles during ap-
plication. Prevent prolonged or repeated inhalation of
vapor or spray mist. If cavity wax vapors are inhaled
and giving respiratory problems, see a doctor immedi-
ately. Use gloves to avoid skin contact. Wash
contaminated skin with soap and water. There are no
OSHA regulations for this product. Always order a
Material Safety Data Sheet when ordering wax.
When applying cavity wax, observe these guidelines:
•Must be done during dry weather.
•Avoid cleaning with water before application of wax.
•If surfaces have been cleaned with water, make
sure they are completely dry before applying wax.
•Surfaces should be clean, dry and free from rust, oil
or metal shavings.
•Treat any corroded areas by removing rust scale,
then prime and paint before application of wax.
Note: When using the work procedures described in this
manual, there will be areas of overspray which may re-
sult in some wax run-off. However, since the application
is done within an enclosure without a visual control of
the coverage, it is better to have some overspray than to
have no coverage.
CAUTION
Do not apply wax in temperatures below 18

C (70

F).
Wax penetration abilities are not enough at lower tem-
peratures and the rustprotection will be inadequate.
Work should be done in a well ventilated area. Cavity
wax is not a toxic product but should not be inhaled. Use
of a breathing mask is recommended while the wax is
being applied.
1821-06-02-01
Rust Prevention, Inspection
Before beginning rust protection inspection, read about
warranty information under “Rustproofing Information”
page 3, basic information under “General Work Proce-
dures”page 11, material under “Specifications”page 5
and equipment under “Tools”page 7.
1
W1000089
Open driver side door. Remove the 4
screws holding the door sill to the
floor. Lift off the door sill. Pull off the
bottom part of the door opening seal.
Lift the edge of the floormat and in-
spect the floor area for rust. Inspect
the floormat for cracks and rips. (In
some applications, a bitumenous mat
is placed under the floormat. Check
along the edges for signs of rust.)
Torx 25
2
W1000090
Remove lower bolt for the door front
grabhandle and pull the handle back.
Remove the A-pillar trim fastener. Re-
move the trim. Remove the rubber
grommet close to the floor. Inspect up
and down A-pillar for signs of rust. Re-
place all removed parts.
12 mm socket,
screwdriver,
mirror,
flashlight
11

Group 18 Rustproofing Service Procedures
3
W1000112
Remove the lower part of the door
rear grab handle. Pull the handle out.
Loosen the back trim by carefully
pulling out the “christmas tree”fas-
tener. Hold up the edge of the carpet
and pull out the lower part of the
B-pillar trim. Inspect the lower part of
the B-pillar for signs of rust. Install the
trim and handle.
16 mm socket,
screwdriver,
mirror,
flashlight
4
W8001398
Remove the knob on the door by
pulling the rubber plug out with a
scriber. Remove the screw.
Torx 10
5
W8001379
If the vehicle is equipped with me-
chanical window regulators, remove
the crank. Lift the vinyl cover in the
wide end and push it to the side. Re-
move the screw.
Torx 25
6
W8001380
Using a small, flatblade screwdriver,
carefully remove the six plugs in the
door panel.
12

Group 18 Rustproofing Service Procedures
7
W8001381
Remove the three bolts and three
screws holding the panel to the door. 14 mm socket,
Torx 25
8
W8001382
The panel is now held in place by the
“christmas tree”fasteners. Carefully
pry the door panel away from the door.
9
Disconnect the electrical connectors
for the electrical equipment in the door
panel. Remove the door panel.
Torx 25
10
W1000091
Inspect the inside, lower half of the
door for signs of rust. Install door
panel.
mirror,
flashlight
11
W1000092
Remove side repeater light lens. Re-
move repeater light base. Pull base
out and let it hang. Through the hole,
inspect the lower cab side for signs of
rust. Install the side light repeater light.
Philips,
Torx 25,
mirror,
flashlight
13

Group 18 Rustproofing Service Procedures
12
W1000093
Sleeper cabs only:
Open luggage door. Locate the vent in
the rear end of door frame. With a
knife blade or small screwdriver, pry
out the center section. Do this by push-
ing the blade in between vent and grill
and push the grill to the side so the
lock tabs release. Pry out the lock tabs
for the vent (2 per side) and remove
the vent. Inspect the lower part of the
C-pillar for signs of rust. Install vent.
mirror,
flashlight
13
W1000094
Inspect the lower part of the luggage
door, inner and outer skin, for signs of
rust.
14
W1000095
Remove plastic plugs along the inside
of the bottom rail. Inspect for signs of
rust on the inside of the bottom rail. In-
stall the plastic plugs.
Generally inspect the floor area under-
neath the cab. Look between the large
fore-aft member and the bottom rails
at the edge of the cab for signs of rust.
mirror,
flashlight
15
Repeat above steps on the other side
of the cab.
16
W1000097
Inspect the rear, lower cab edge for
signs of rust. mirror, flashlight
14

Group 18 Rustproofing Service Procedures
17
W1000096
Inspect around the bottom corners of
the windshield for signs of rust.
1821-09-02-02
Rust Prevention, Retreatment
(Complete Cab)
Daycab
Before beginning rust prevention retreatment, read about
warranty information under “Rustproofing Information”
page 3, basic information under “General Work Proce-
dures”page 11, material under “Specifications”page 5,
application techniques under “Application”page 10 and
equipment under “Tools”page 7.
1
W0001585
Assemble the wax spray kit as shown
in the illustration. The fluid tank is
equipped with two air pressure regula-
tors and two hoses that connects to
the spray gun. The red hose supplies
air and the black hose supplies wax to
the spray gun.
2
Set both regulators to approximately
the same pressure for proper opera-
tion. Start with 175 kPa (25 psi). Fully
depress the spray gun trigger and ob-
serve the spray pattern at the tip of
the application wand. The pattern
should be shaped as a 360

cone with
a single stream in the middle. With the
pressures properly regulated, there
should be some misting of the cavity
wax. This will help ensure that all sur-
faces are coated. Adjust as necessary
to get the proper spray pattern. If the
spray pattern is not symmetrical, it
may be necessary to clean the tip.
See the spray gun operation manual.
15

Group 18 Rustproofing Service Procedures
3
W1000100
Open the door. Push back the door
wiring grommet and insert the applica-
tion wand down the A-pillar and into
the bottom rail, pointing rearward. The
total length of the wand should be in-
serted.
Fully depress the spray gun trigger
then slowly pull the application wand
back out from the bottom rail and
A-pillar at the determined speed. Re-
lease the spray gun trigger as soon as
the tip of the wand appears at the
door wiring grommet. Refit the grom-
met and adjust to a good fit.
Cavity wax
spray kit
4
W1000101
Remove the door switch for the interior
light. Insert the application wand in
through the switch hole forward into
the bottom rail cavity. The total length
should be inserted.
Fully depress the spray gun trigger,
then slowly pull the application wand
back out from the bottom rail at the
determined speed. Release the spray
gun trigger as soon as the tip of the
wand appears at the door switch hole.
Torx 25,
Cavity wax
spray kit
5
W1000102
Insert the application wand up the
B-pillar, through the door switch hole,
to a minimum position of 400 mm
(1 1/3 ft) up the cavity.
Fully depress the spray gun trigger,
then slowly pull the application wand
back out from the B-pillar at the deter-
mined speed. Release the spray gun
trigger as soon as the tip of the wand
appears at the door switch hole. Install
the light switch.
Torx 25,
Cavity wax
spray kit
16

Group 18 Rustproofing Service Procedures
6
W1000104
Remove the side repeater lamp lens
and base. Coat the cavity behind the
lamp. Move the wand as necessary to
ensure complete coverage, both on
the bottom and the panel side. Install
the repeater lamp.
Philips,
Torx 25,
Cavity wax
spray kit
7
W8001398
Remove the knob on the door by
pulling the rubber plug out with a
scriber. Remove the screw.
Torx 10
8
W8001379
If the vehicle is equipped with me-
chanical window regulators, remove
the crank. Lift the vinyl cover in the
wide end and push it to the side. Re-
move the screw.
Torx 25
9
W8001380
Using a small, flatblade screwdriver,
carefully remove the six plugs in the
door panel.
17

Group 18 Rustproofing Service Procedures
10
W8001381
Remove the three bolts and three
screws holding the panel to the door. 14 mm socket,
Torx 25
11
W8001382
The panel is now held in place by the
“christmas tree”fasteners. Carefully
pry the door panel away from the door.
12
Lift the upholstery away from the door.
Disconnect the electrical connectors
for the electrical equipment in the door
panel. Remove the door panel.
Torx 25
13
Note the position of wiring that may be
taped to the cover plate. Remove tape
to free the wiring. To aid in reassem-
bly, note the position of any missing
cover plate screws that were removed
during door upholstery removal. Re-
move the cover plate screws and then
remove the cover plate.
Torx 25
14
W1000105
Coat the lower door cavity with cavity
wax up to 50 mm (2 in.) from the
bottom. With the application wand in-
serted in the door cavity, move the
wand as necessary to ensure com-
plete coverage.
Cavity wax
spray kit
15
Install the cover plate. Do not allow
any wiring to be pinched between
plate and door. Leave the proper
screw holes empty for the door uphol-
stery installation. See step 13. Tape
wiring to the cover plate as necessary.
Torx 25
18