Volvo VNL 780 User manual

OPERATOR'S MANUAL
vhd,vn
Volvo Trucks. Driving Success.
R
OPERATOR'S MANUAL
vhd,vn

CALIFORNIA PROPOSITION 65 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.
CALIFORNIA PROPOSITION 65 WARNING
Battery posts, terminals and other related accessories contain lead
and lead compounds, chemicals known to the State of California to
cause cancer and other reproductive harm.
Batteries also contain other chemicals known to the State of California
to cause cancer.
Wash hands after handling.
IMPORTANT
Your new Volvo truck contains many new technological advancements
that may require new servicing techniques and methods. An authorized
Volvo truck dealer is in the best position to provide technicians who
have the necessary training, experience and tools to properly service
your truck.
© Volvo Group North America, Inc. 2009
calprop.fm Page 1 Tuesday, July 8, 2008 9:09 AM

i
VN, VHD SERIES
OPERATOR’S HANDBOOK
THE INFORMATION CONTAINED IN THIS HANDBOOK IS
CURRENT AT TIME OF PUBLICATION.
© Volvo Group North America, Inc. 2009
VN,VHDcover.fm Page i Tuesday, July 1, 2008 9:46 AM

NOTES
ii
VN,VHDcover.fm Page ii Tuesday, July 1, 2008 9:46 AM

Contents
INTRODUCTION ............................................................................... 1
............................................................................................................ 1
ADVISORY LABEL DEFINITIONS (IN HANDBOOK) .............. 1
INFORMATION FOR THE OWNER ............................................. 2
EMISSIONS CONTROL COMPLIANCE ...................................... 5
Exhaust and Noise Emissions ........................................................ 5
B20 Approval For Volvo EPA 07 Certified Products .................... 6
CALIFORNIA EMISSION CONTROL SYSTEMS
WARRANTY ................................................................................... 7
MANUFACTURER’S WARRANTY COVERAGE: ...................... 7
OWNER’S WARRANTY RESPONSIBILITIES: ........................... 8
Qualifications and Limitations: ..................................................... 9
CALIFORNIA EMISSION CONTROL SYSTEMS
SERVICE RECORD .................................................................... 15
GASEOUS EMISSION CONTROL SYSTEMS WARRANTY . 16
Qualifications and Limitations: ................................................... 17
ENGINE GASEOUS EMISSIONS CONTROL SYSTEM
WARRANTY ............................................................................... 17
FEDERAL EMISSION REQUIREMENTS ................................ 19
VEHICLE DATA ........................................................................... 26
Identification and Labels ............................................................. 26
SERVICE LITERATURE .............................................................. 31
SERVICE ASSISTANCE .............................................................. 32
REPORTING SAFETY DEFECTS ............................................... 33
United States ............................................................................... 33
Canada ......................................................................................... 33
Mexico ......................................................................................... 33
EVENT DATA RECORDING DEVICES ..................................... 34
SAFETY INFORMATION .............................................................. 35
GENERAL SAFETY INFORMATION ........................................... 35
Operating the Vehicle ..................................................................... 35
Operating in Bobtail Mode ............................................................ 36
VORAD®COLLISION WARNING SYSTEM ............................. 38
ADVISORY LABELS ................................................................... 39
CAB ENTRY AND EXIT .............................................................. 40
General ......................................................................................... 40

General Entry Guidelines ............................................................ 43
Driver Side Entry/Exit ................................................................. 44
ENTERING SLEEPER FROM SEAT ........................................... 50
Standard Gear Lever .................................................................... 50
SAFETY EQUIPMENT ................................................................ 52
Warning Triangles, Day Cab ....................................................... 53
Sleeper Cab .................................................................................. 54
SAFETY BELT SYSTEM ............................................................. 55
SRS AIRBAG ................................................................................ 56
SRS System ................................................................................. 56
INSTRUMENTS AND CONTROLS .............................................. 65
CAB INTERIOR .............................................................................. 65
INSTRUMENT PANEL ................................................................... 66
Tell-Tales ........................................................................................ 66
Colors ............................................................................................. 66
Panel Arrangement ......................................................................... 67
INSTRUMENT PANEL GAUGE LAYOUT ................................. 68
Panel A ........................................................................................... 69
Panel B ........................................................................................... 70
Panel C .......................................................................................... 72
Panel D ........................................................................................... 73
Panel E ........................................................................................... 74
Tachometer ..................................................................................... 78
Upper Tell-Tales ............................................................................. 78
Speedometer ................................................................................... 78
Front and Rear Brake System Air Pressure Gauges ...................... 78
Oil Pressure Gauge ......................................................................... 79
Coolant Temperature Gauge .......................................................... 81
Middle and Lower Tell-Tales ......................................................... 81
Driver Information Display (DID) ................................................. 81
Fuel Level Gauge ........................................................................... 81
Voltmeter Gauge (Basic Level Cluster Only) ................................ 82
Intake Manifold Pressure Gauge (High Level Cluster Only) ......... 82
Application Air Pressure Gauge (High Level Cluster Only) ......... 82
Exhaust Pyrometer Gauge (High Level Cluster Only) .................. 83
Exhaust Pyrometer Gauge (High Level Cluster Only) .................. 83
DASH SWITCHES ...................................................................... 107
Power Take-Off (PTO) ............................................................... 107

CLIMATE CONTROL SYSTEMS ........................................... 114
AIR CONDITIONING MANUAL CLIMATE CONTROL
(MCC) .......................................................................................... 119
SLEEPER CLIMATE UNIT ........................................................ 123
LIGHT CONTROL PANEL ........................................................ 124
SLEEPER CONTROL PANEL (SLEEPER MODELS ONLY) .. 127
Sleeper Control Panel, High ...................................................... 130
Sleeper Control Panel, Basic ..................................................... 132
MISCELLANEOUS CAB EQUIPMENT ................................... 140
STEERING COLUMN ................................................................ 143
ADJUSTABLE STEERING COLUMN ...................................... 146
STEERING WHEEL CONTROLS ............................................. 147
MISCELLANEOUS SWITCHES ............................................... 149
INTERIOR LIGHTS .................................................................... 150
Fresh Air Vent ............................................................................ 154
CAB VENTILATION, SLEEPER ............................................... 155
Inverter Switch ? 12 V DC to 120 V AC ................................... 162
PARKING HEATER (OPTIONAL, SLEEPER MODELS
ONLY) .......................................................................................... 171
ANTENNAS ................................................................................ 174
TELEVISION .............................................................................. 176
COMMUNICATION EQUIPMENT ........................................... 178
STORAGE COMPARTMENTS .................................................. 180
SLEEPER BUNKS ...................................................................... 193
VN 780, VNL 730, VN 670 OFFICE .......................................... 209
SLEEPER COMPARTMENT SINK ........................................... 211
OPERATION ................................................................................... 217
PRE-TRIP INSPECTION AND DAILY MAINTENANCE .......... 217
Pre-Trip Assistance ................................................................... 218
HOOD OPERATION ................................................................... 241
SAFETY BELTS .......................................................................... 259
Safety Restraint VN 430, VN 630, VN 670 and VHD 430 ....... 268
SEATS, GENERAL ..................................................................... 283
NATIONAL STANDARD SEAT ................................................. 284
NATIONAL COMFORT SEAT ................................................... 285
PASSENGER SEATS .................................................................. 287
ENGINE OPERATION ................................................................ 291
IMMOBILIZER FEATURE ........................................................ 292

CONTROL AWARENESS FEATURE ........................................ 294
FUEL ECONOMY DRIVING ..................................................... 295
CRUISE CONTROL .................................................................... 302
Volvo Engine Brake (I-VEB) ..................................................... 304
BRAKE OPERATION ................................................................. 305
Parking Brake/Trailer Supply Valves ......................................... 314
Trailer Brake Hand Control ....................................................... 320
ANTI-LOCK BRAKING SYSTEM (ABS) ................................ 322
VOLVO ENHANCED STABILITY TECHNOLOGY ................ 324
TRACTION CONTROL SYSTEM (TCS) (OPTIONAL) ........... 324
VEHICLE SPEED RETARDING DEVICES .............................. 326
Transmission Retarder, VHD Only ............................................ 327
STARTING THE ENGINE .......................................................... 329
COLD WEATHER OPERATION ............................................... 340
FIFTH WHEEL INSTRUCTIONS .............................................. 347
Operating the Fifth Wheel Slider ............................................... 368
PERFORMANCE BONUS FEATURE ....................................... 372
Performance Bonus Guide ......................................................... 374
AXLES ......................................................................................... 378
DIESEL PARTICULATE FILTERS (IF EQUIPPED) ................. 382
MAINTENANCE AND LUBRICATION ..................................... 399
DAILY MAINTENANCE .............................................................. 399
TOWING PROCEDURE ............................................................... 400
Caging Spring Brake Chambers ................................................ 408
ENGINE OIL LEVEL CHECK ................................................... 416
POWER STEERING, GENERAL ............................................... 418
COOLING SYSTEM ................................................................... 422
CAB AIR FILTERS ..................................................................... 423
HEADLIGHTS ............................................................................ 424
ROOF EXTENDER ..................................................................... 427
FRONT BUMPER/LICENSE PLATE MOUNTING .................. 430
MODIFICATIONS TO VEHICLE .............................................. 433
WHEELS ..................................................................................... 435
BATTERY .................................................................................... 439
Battery Voltage Protection System ............................................ 450
ELECTRICAL ............................................................................. 453

Safety 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 handling information
in this manual. Be certain that you fully
understand and follow all safety warnings.
IT IS IMPORTANT THAT THE
FOLLOWING INFORMATION BE
READ, UNDERSTOOD AND ALWAYS
FOLLOWED.
The following types of advisories are used
throughout this manual:
DANGER
Danger indicates an unsafe practice that
could result in serious personal injury or
death. A danger advisory banner is in
white type on a black background with
ablack border.
WARNING
Warning indicates an unsafe practice that
could result in personal injury. A warning
advisory banner is in black type on a
gray background with a black border.
CAUTION
Caution indicates an unsafe practice that
could result in damage to the product. A
caution advisory is in black type on a
white background with a black border.
Note: Note indicates a procedure, practice,
or condition that must be followed in order
for the vehicle or component to function in
the manner intended.

INTRODUCTION 1
ADVISORY LABEL DEFINITIONS (IN HANDBOOK)
Cautionary signal words (Danger-Warning-Caution) may appear in various locations
throughout this manual. Information accented by one of these signal words must be observed
to minimize the risk of personal injury to service personnel, or the possibility of improper
service methods which may damage the vehicle or cause it to be unsafe. Additional Notes
and Service Hints are used to emphasize areas of procedural importance and provide
suggestions for ease of repair. The following definitions indicate the use of these advisory
labels as they appear throughout the manual:
DANGER
Danger indicates an unsafe practice that
could result in serious personal injury or
death. A danger advisory banner is in
white type on a black background with
ablack border.
WARNING
Warning indicates an unsafe practice that
could result in personal injury. A warning
advisory banner is in black type on a
gray background with a black border.
CAUTION
Caution indicates an unsafe practice that
could result in damage to the product. A
caution advisory is in black type on a
white background with a black border.
Note: Note indicates a procedure, practice,
or condition that must be followed in order
for the vehicle or component to function in
the manner intended.

2 INTRODUCTION
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 necessary, your
dealer will contact the manufacturer for any assistance
In addition to this operator’s manual, there may be additional instruction/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.
Various safety labels may be placed about the components by the component manufacturer.
Be sure to read and follow these labels to prevent damage to the vehicle, personal injury
or death.
Information in this manual refers to Volvo components and Volvo drivetrain. There is
also certain information regarding the Cummins engine. For detailed information on
the Cummins engine or non-Volvo engines and/or drivetrains, contact the respective
manufacturer.
Establish a Preventive Maintenance Program 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 running, resulting in longer component life. This makes for a safer vehicle
by reducing any mechanical failures due to poor maintenance practices.
Various truck warranty coverage plans, contingent on application and weight class, are
available. Please contact an authorized Volvo Truck dealer for complete details. Replacement
warranty certificates for Volvo Trucks are available from authorized Volvo dealers.
For trucks placed in service after October, 2002 and operating in the USA, Mexico and
Canada, Volvo dealers can order copies of the Standard Truck Warranty Certificate and the
Premium (Purchased) Truck Coverage Certificate. Warranty Certificate copies and Operator
Manuals are available in either English, Spanish or French. Contact your authorized Volvo
Truck dealer for more information.
Note: Federal law requires manufacturers to notify owners of its products in the event of
a non-compliance to a Federal Motor Vehicle Safety Standard or if a safety-related defect
is discovered. If you are not the original owner of this vehicle, 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
Attn: Vehicle Registration Dept.
P.O. Box 26115
Greensboro, NC 27402-6115
United States of America

INTRODUCTION 3
DO NOT Remove this operator’s manual from the vehicle. It contains important operational
and safety information that is needed by all drivers and owners of this vehicle.
Note: Illustrations in this manual are used for reference only and may differ slightly from
the actual vehicle; however, key components addressed in the manual are represented as
accurately as possible.
This manual covers Volvo VN and VHD series vehicles manufactured by Volvo Trucks
North America with any of the following designations:
•VNL 780
•VNL 730
•VNL 670
•VNL 630
•VNL 430
•VNL 300 (Daycab)
•VNM 630
•VNM 430
•VNM 200 (Daycab) Roof fairing choice is optional.
•VHD 200B (Axle Back)
•VHD 200F (Axle Forward)
•VHD 430 (Axle Back)
•VHD 430 (Axle Forward)

4 INTRODUCTION
W0028048

INTRODUCTION 5
EMISSIONS CONTROL COMPLIANCE
Exhaust and Noise Emissions
General
USA
The Federal Clean Air Act, Section 203 (a) (3), states the following concerning the removal
of air pollution control devices or modification of a certified engine to a non-certified
configuration:
(3) For any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under
this part prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or
dealer knowingly to remove or render inoperative any such design after sale and delivery to
the ultimate purchaser.”
Specifically, please note that no person may make such changes prior to the sale and delivery
of the vehicle to the ultimate purchaser, and, in addition, no manufacturer or dealer may take
such action after sale and delivery of the vehicle to the ultimate purchaser. The law provides
a penalty of up to $10, 000 for each violation.
Canada
The same conditions that apply in the USA apply to Canada, with one exception. After the
vehicle is sold to a retail customer, that is, the end user, the jurisdiction controlling the
emission control devices becomes the province in which the vehicle is licensed. No changes
should be made that render any or all of the devices inoperative.
If the owner/operator wishes to make changes to the emission control devices, check with
the provincial authority before changes are made.
Mexico
The same conditions that apply in the USA apply to Mexico. Refer to the Mexican Federal
Law for Emission Control which adheres to EPA regulations. No changes should be made
that render any or all of the emissions control devices inoperative.
If the owner/operator wishes to make changes to the emission control devices, check with
the state authority before changes are made.

6 INTRODUCTION
B20 Approval For Volvo EPA 07 Certified Products
Volvo engines are certified to comply with U.S. EPA and California emissions standards
based upon the use of test fuels with specifications established by these regulatory agencies.
Alternative fuels, including biodiesel, that are not substantially similar to the required test
fuels may adversely affect engine emissions compliance. As a result, Volvo does not warrant
the engine will conform to applicable Federal or California emissions limits when operated
on biodiesel or other alternative fuels that are not substantially similar to specified test
fuels used for certification.
However, the use of biodiesel up to a maximum of 20% (B20) in and of itself, will not
affect the manufacturer’s mechanical warranty as to engine and emissions system related
components, provided the bio fuel used in the blend conforms to ASTM D6751, B1 to B5
blends conform to ASTM D975, and B6 to B20 blends conform to ASTM D7467.

INTRODUCTION 7
CALIFORNIA EMISSION CONTROL SYSTEMS
WARRANTY
Note: Warranty coverage is subject to change without notice. Contact your Volvo Truck
dealer for the current warranty statement.
The California Air Resources Board and Volvo Trucks North America are pleased to
explain the California emission control system warranty on your new motor vehicle engine.
In California, new motor vehicle engines must be designed, built and equipped to meet
the State’s stringent anti-smog standards. Volvo Trucks North America must warrant the
emission control system on your engine for the period of time listed below provided there
has been no abuse, neglect, or improper maintenance of your engine.
Your emission control system may include parts such as the fuel-injection system,
turbocharger assembly, electronic control module and other emission-related assemblies.
Where a warrantable condition exists, Volvo Trucks North America will repair your engine
at no cost to you including diagnosis, parts, and labor.
MANUFACTURER’S WARRANTY COVERAGE:
If an emission-related part of your engine is defective, the part will be repaired or replaced
by Volvo Trucks North America. This is your emission control system DEFECTS
WARRANTY.

8 INTRODUCTION
OWNER’S WARRANTY RESPONSIBILITIES:
As the motor vehicle engine owner, you are responsible for the performance of the required
maintenance listed in this manual. Volvo Trucks North America recommends that you retain
all receipts covering maintenance of your vehicle, but Volvo Trucks North America cannot
deny warranty solely for the lack of receipts or for your failure to ensure the performance of
all scheduled maintenance listed in other manuals which were supplied with your vehicle.
You are responsible for presenting your motor vehicle engine to a VOLVO dealer as soon
as a problem exists. The warranty repairs should be completed in a reasonable amount of
time, not to exceed 30 days.
As the motor vehicle engine owner, you should also be aware that Volvo Trucks North
America may deny you warranty coverage if your vehicle or a part has failed due to abuse,
neglect, improper maintenance, or unapproved modifications.
If you have any questions regarding your warranty rights and responsibilities, you should
contact the Volvo Trucks North America Warranty Department at P. O. Box 26115,
Greensboro, NC 27402–6115, or the California Air Resources Board at 9480 Telstar Avenue,
El Monte, California 91731.
(Applicable only to vehicles and/or engines certified for sale and registered in the
State of California)
Volvo Trucks North America warrants the Emission Control Systems on each new VOLVO
diesel engine in a new VOLVO truck to comply with all State of California emissions
regulations applicable at the time of manufacture of the engine, and to be free from defects in
material and workmanship under normal use and service up to 60 months, or 100,000 miles,
or 3,000 engine operating hours, whichever occurs first, provided all Volvo Trucks North
America maintenance requirements are followed as described in this manual. All warranty
periods are calculated from the date-in-service of the new vehicle. The repair or replacement
of defective parts will be made without charge for the cost of parts and, if repairs are made at
an authorized Volvo Trucks North America dealership, there will be no charge for labor.
Volvo Trucks North America’s obligation under this warranty is limited to the repair or
replacement, at Volvo Trucks North America’s option, of any part(s) of the Emission Control
Systems of such engine and/or vehicle found to be defective upon examination by Volvo
Trucks North America and provided that such part(s) were returned to Volvo Trucks North
America or its nearest authorized Dealer within a reasonable period of time.

INTRODUCTION 9
Qualifications and Limitations:
Not covered by the Emissions Control
Systems Warranty:
•Malfunctions caused by misuse, improper adjustments, modification, alteration,
tampering, disconnection, improper or inadequate maintenance and use of improper
diesel fuel.
•Damage resulting from accident, acts of nature or other events beyond the control of
Volvo Trucks North America.
•Inconvenience, loss of use of the vehicle, commercial loss of any kind including, but
not limited to, consequential, incidental damages.
•Any vehicle in which the odometer has been altered or damaged so that mileage cannot
be readily determined.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES
AND REPRESENTATIONS OR CONDITIONS, STATUTORY OR OTHERWISE,
EXPRESSED OR IMPLIED INCLUDING, BUT NOT LIMITED TO, IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
PROCEDURES FOR HANDLING EMISSIONS CONTROL SYSTEM WARRANTY
The following engine components are covered by the supplemental emissions control system
warranty policy as required by the California Code of Regulations.

10 INTRODUCTION
1 Turbocharger Assembly
2 VGT Actuator Control Valve
3 Charge Air Cooler
4 Unit Injectors
5 Engine Wiring Harness
6 Electronic Control Module
7 EGR Mixer
8 EGR Cooler
9 Crankcase Breather
10 Diesel Particulate Filter (DPF)
Assembly
11 DPF Components:
•Aftertreatment Hydrocarbon
Injector (AHI)
•AHI Shutoff Valve
•Discharge Recirculation Valve
•DRV Solenoid Valve
•Pre-Catalyst Temp. Sensor
•Post-Catalyst Temp. Sensor
•Downstream DPF Temp. Sensor
•Differential Pressure Sensor