Volvo D13F, D11F User Manual

OPERATOR'S MANUAL

VEHICLE MAINTENANCE

VN,VHD

Volvo d11f and d13f engines

Volvo Trucks. Driving Success.

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Table of Contents i

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Warning Label Information . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Information for the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Exhaust and Noise Emissions . . . . . . . . . . . . . . . . . . . . . . . . 5

Label Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fuse and Relay Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Proper Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . 24

Injury Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Engine Damage Prevention . . . . . . . . . . . . . . . . . . . . . . . . . 34

Electric System Damage Prevention . . . . . . . . . . . . . . . . . . 36

Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . 38

General Engine Information . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Engine Overview, D11F and D13F Left Side View . . . . . . 39

Engine Overview, D11F and D13F Right Side View . . . . . 40

Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Engine Components, Service Schedules . . . . . . . . . . . . . . . 43

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Diesel Particulate Filters (If Equipped) . . . . . . . . . . . . . . . 65

Fan and Auxiliary Drive Belts . . . . . . . . . . . . . . . . . . . . . . 66

Turbocharger and Charge Air Cooler . . . . . . . . . . . . . . . . . 68

Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Transmission, Clutch and Rear Axle Maintenance . . . . . . . 73

Steering and Brakes Maintenance . . . . . . . . . . . . . . . . . . . . 76

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . 80

Tires, Wheels and Hub Maintenance . . . . . . . . . . . . . . . . . 82

Chassis Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Cab Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Oil Capacity Tables and Viscosity Charts . . . . . . . . . . . . 108

ii Table of Contents

Service Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Service Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Scheduled Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Repair Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Tire Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Fuel and Oil Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Service Assistance and Manuals . . . . . . . . . . . . . . . . . . . . 122

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Foreword 1

FOREWORD

DO NOT Remove this manual from the vehicle. It contains important
operational and safety information that is needed by all drivers and owners of
this vehicle.

This manual contains information concerning the safe operation of your
vehicle. It is extremely important that this information is read and understood
before the vehicle is operated. This manual also contains a considerable
amount of information concerning the vehicle, such as vehicle identification,
Preventive Maintenance recommendations and a log for your service records.
Please keep this in the vehicle at all times. Information from other component
manufacturers is supplied in separate manuals in the Owner's Package.

It is important that this manual stay with the vehicle when it is sold. Important
safety information must be passed on to the new customer. 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 should be informed immediately if you believe that the
vehicle has a defect that could cause a crash, injury or death.

Contact NHTSA by calling the Auto Safety Hotline at 1 [phone], by
writing to NHTSA, U.S. Department of Transportation, Washington, DC
20590, by TTY at 1 [phone], or visit their website at
www.nhtsa.dot.gov.

Volvo Trucks North America

Greensboro, NC USA

Order number: PV776-21012002

©2008 Volvo Trucks North America, 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.

2 Foreword

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
handling information in this Operator's Manual. Be certain that you fully
understand and follow all safety warnings. It is extremely important that
this information is read and understood before the vehicle is operated.

IT IS IMPORTANT THAT THE FOLLOWING INFORMATION
CONCERNING LABELS BE READ, UNDERSTOOD AND ALWAYS
FOLLOWED.

The following types of labels are used throughout this manual:

A note defines an operating procedure, practice, condition, etc., which is
essential to proper operation of the vehicle.

A danger label directs the operator's attention to unsafe practices which
could result in serious personal injury or death. The danger label is in white
type on a black background with a black border.

A warning label directs the operator's attention to unsafe practices which
could result in personal injury or severe damage to the vehicle. The
warning label is in black type on a gray background with a black border.

A caution label directs the operator's attention to unsafe practices where
personal 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 and Advisory Labels

Advisory, Danger, Warning and Caution labels are placed in various locations
of the vehicle to alert drivers and service technicians about situations that may
lead to personal injury or equipment damage. In the event that a label is
damaged or missing the label must be replaced. Contact your authorized
Volvo Truck dealer for assistance regarding Warning and Advisory labels.

General Information 3

GENERAL INFORMATION

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 Volvo Trucks North
America or other manufacturers for any assistance.

In addition to this Maintenance 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.

Also, various safety labels may be placed on components by the component
manufacturer. 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.
There is also certain information regarding the Cummins engine. For detailed
information on the Cummins engine or non-Volvo engines and/or drivetrains
contact your nearest Volvo Truck dealer.

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.

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 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

P. O. Box 26115

Greensboro, NC 27402-6115

United States of America

4 General Information

This Maintenance Manual covers all Volvo vehicles manufactured by Volvo
Trucks North America, including the whole chassis and all Volvo
manufactured components. For specific maintenance information on vendor
components, manufactured by, for example: Cummins, Fuller, Meritor, etc.,
see the respective manufacturer's service and maintenance literature.

This manual, together with manuals for specific components (for example,
Volvo engine, Cummins engine, Eaton transmission, 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 specifications contained in this manual are
based upon the latest product information available at the time of publication.
If any questions arise concerning the current status of Federal or state laws,
the appropriate Federal or state agency should be contacted.

Illustrations are used for reference only and may differ slightly from the actual
vehicle, however, key components addressed in this manual are represented as
accurately as possible.

Volvo Trucks North America reserves the right to make changes at any time or
to change specifications or design without notice and without incurring
obligation.

General Information 5

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:

“The following acts and the causing thereof are prohibited:

(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.

Should the owner/operator wish to make any changes to the emission control
devices, check with the provincial authority before making any such changes.

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.

Should the owner/operator wish to make any changes to the emission control
devices, check with the state authority before making any such changes.

6 General Information

CALIFORNIA EMISSION CONTROL SYSTEMS WARRANTY

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.

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.

General Information 7

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.

Qualifications and Limitations:

Not covered by the Emissions Control Systems Warranty:

앫 Malfunctions caused by misuse, improper adjustments, modification,

alteration, tampering, disconnection, improper or inadequate maintenance
and use of improper diesel fuel.

앫 Damage resulting from accident, acts of nature or other events beyond the

control of Volvo Trucks North America.

앫 Inconvenience, loss of use of the vehicle, commercial loss of any kind

including, but not limited to, consequential, incidental damages.

앫 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.

8 General Information

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.

a. Turbocharger Assembly

b. VGT Actuator Control Valve

c. Charge Air Cooler

d. Unit Injectors

e. Engine Wiring Harness

f. Electronic Control Module

g. EGR Mixer

h. EGR Cooler

i. EGR Control Valve

j. Crankcase Breather

k. Diesel Particulate Filter (DPF) Assembly

l. DPF Components:

앫 Aftertreatment Fuel Injector (AFI)

앫 AFI Shutoff Valve

앫 Discharge Recirculation Valve

앫 Pre-Catalyst Temp. Sensor

앫 Post-Catalyst Temp. Sensor

앫 Downstream DPF Temp. Sensor

앫 Differential Pressure Sensor

m. Sensors:

앫 Engine Timing/Speed (flywheel)

앫 Engine Position (camshaft)

앫 Temperature — Coolant

앫 Temperature — Inlet Manifold Air

앫 Pressure — Boost Air

앫 Humidity

앫 EGR Temperature

앫 EGR Differential Pressure

General Information 9

The emission warranty for the diesel particulate filter covers defects in
workmanship only. Normal maintenance, such as cleaning ash from the filter
at regular maintenance intervals, is not covered by the emission warranty.

In response to customer requests, Volvo Trucks North America may build
vehicles with engines supplied by other manufacturers, including, but not
limited to, Cummins. In these cases, each engine manufacturer through its
service organization, is responsible for emission control systems warranty on
all parts of the engine assembly, as furnished.

Any unauthorized adjustments to the emission control components can cause
severe damage to the engine.

1. Repairs by VOLVO Dealers, Sub-Dealers and Service Dealers

Repairs covered by the California Emission Control Systems Warranty
will be performed by any authorized VOLVO repair facility at his place
of business with no charge for parts and labor (including diagnosis),
using VOLVO parts for any part of the emission control systems covered
by this warranty and found defective.

2. In an Emergency

In an emergency, where an authorized VOLVO facility is not available,
repairs may be performed at any available service establishment, or by
the owner, using any replacement part, within the limitations of
paragraphs 4 and 5 in this section. An emergency condition exists under
this section if, after 30 days, repairs have not been completed or parts
are not yet available. VOLVO will reimburse the owner for such repairs
that are covered under this warranty, including diagnosis, not to exceed
VOLVO’s suggested retail price for parts replaced and labor charges
based on VOLVO’s recommended time allowance and geographically
appropriate hourly labor rate. Replaced parts and paid invoices must be
presented at a VOLVO facility as a condition of reimbursement for
emergency repairs performed elsewhere.

10 General Information

In the event that damage results from unauthorized adjustments to any
emission control system components, as evidenced by settings other than as
specified, or broken fastener seals, the cost of repairing such damage WILL
NOT BE COVERED under warranty.

3. Repairs by Non-VOLVO Facilities
Owners may elect to have maintenance, replacement, or repair of

emission control systems performed by any repair facility, and may elect
to use parts other than VOLVO parts without invalidating the warranty
on other components, but the cost of such service or parts will not be
covered by VOLVO under its warranty.

4. Use of Non-VOLVO Parts
Use of replacement parts which are not the equivalent of VOLVO parts

may impair the effectiveness of emission control systems. If other than
VOLVO parts are used, the owner should obtain assurances that such
parts are warranted by their manufacturer to be the equivalent of
VOLVO parts in performance and durability. VOLVO assumes no
liability under this warranty with respect to parts other than VOLVO
parts; however, the use of non-VOLVO parts does not invalidate the
warranty on other components unless non-VOLVO parts cause damage
to warranted parts.

5. Maintenance and Maintenance Records
The vehicle owner is responsible for the performance of all required

maintenance specified in this manual.
VOLVO will not deny a warranty claim solely because there is no record

of maintenance; however, VOLVO may deny a warranty claim if failure
to perform required maintenance results in the failure of a warranted
part. Receipts or other records covering the performance of scheduled
maintenance should be retained to answer questions that may arise
concerning maintenance. Maintenance records should be transferred to
subsequent owners if the vehicle is sold.

6. Items Not Covered by the Emission Control Systems Warranty
— Malfunctions caused by misuse, improper adjustments,

modification, alteration, tampering, disconnection, improper or
inadequate maintenance.

— Damage resulting from accident, acts of nature or other events

beyond the control of VOLVO.
— Inconvenience, loss of use of the vehicle, or commercial loss.
— Any vehicle on which the odometer has been changed so that

mileage cannot be readily determined.

General Information 11

7. Customer Assistance

Volvo Trucks North America wishes to assure that the California
Emission Control Systems Warranty is properly administered. In the
event that owners do not receive the warranty service to which they
believe they are entitled under the California Emission Control Systems
Warranty, they should contact Volvo Trucks North America Warranty
Administration, [phone]. The address and telephone number of
each Regional Office is in your vehicle owner's package. Owners in
need of additional assistance or information concerning the California
Emission Control Systems Warranty may also contact:

Volvo Trucks North America

Warranty Administration

[phone]

12 General Information

CALIFORNIA EMISSION CONTROL SYSTEMS SERVICE
RECORD

CALIFORNIA EMISSION CONTROL SYSTEMS SERVICE RECORD

DATE KM\MILES SERVICE PERFORMED SERVICED BY

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

__/__/__

General Information 13

GASEOUS EMISSION CONTROL SYSTEMS WARRANTY

For emission control systems information on engines other than VOLVO, refer
to the engine vendor’s publications.

Volvo Trucks North America warrants the Emission Control Systems on each
new VOLVO diesel engine in a new VOLVO truck to comply with all United
States Federal and Canadian 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, 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 data-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.

Qualifications and Limitations:

Not covered by the Emissions Control Systems Warranty:

앫 Malfunctions caused by misuse, improper adjustments, modification,

alteration, tampering, disconnection, improper or inadequate maintenance
and use of improper diesel fuel.

앫 Damage resulting from accident, acts of nature or other events beyond the

control of Volvo Trucks North America.

앫 Inconvenience, loss of use of the vehicle, commercial loss of any kind

including, but not limited to, consequential, incidental damages.

앫 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.

14 General Information

ENGINE GASEOUS EMISSIONS CONTROL SYSTEM
WARRANTY

FEDERAL EMISSION REQUIREMENTS

The following engine components are covered by the supplemental emissions
control system warranty policy as required by the Federal emissions
regulations.

a. Turbocharger Assembly

b. VGT Actuator Control Valve

c. Charge Air Cooler

d. Unit Injectors

e. Engine Wiring Harness

f. Electronic Control Module

g. EGR Mixer

h. EGR Cooler

i. EGR Control Valve

j. Crankcase Breather

k. Diesel Particulate Filter (DPF) Assembly

l. DPF Components:

앫 Aftertreatment Fuel Injector (AFI)

앫 AFI Shutoff Valve

앫 Discharge Recirculation Valve

앫 Pre-Catalyst Temp. Sensor

앫 Post-Catalyst Temp. Sensor

앫 Downstream DPF Temp. Sensor

앫 Differential Pressure Sensor

m. Sensors:

앫 Engine Timing/Speed (flywheel)

앫 Engine Position (camshaft)

앫 Temperature — Coolant

앫 Temperature — Inlet Manifold Air

앫 Pressure — Boost Air

앫 Humidity

앫 EGR Temperature

앫 EGR Differential Pressure

General Information 15

The emission warranty for the diesel particulate filter covers defects in
workmanship only. Normal maintenance, such as cleaning ash from the filter
at regular maintenance intervals, is not covered by the emission warranty.

In response to customer requests, Volvo Trucks North America may build
vehicles with engines supplied by other manufacturers, including, but not
limited to, Cummins. In these cases, each engine manufacturer through its
service organization, is responsible for emission control systems warranty on
all parts of the engine assembly, as furnished.

FEDERAL EMISSION REQUIREMENTS

This section covers the requirement of the United States Clean Air Act which
states:

“The manufacturer shall furnish with each new motor vehicle or motor vehicle
engine such written instructions for the maintenance and use of the vehicle or
engine by the ultimate purchaser as may be reasonable and necessary to assure
the proper functioning of emission control devices and systems.”

This section also covers the requirements of the emissions regulations
promulgated under the Motor Vehicle Safety Act in Canada.

TAMPERING WITH GASEOUS EMISSION CONTROL SYSTEMS
PROHIBITED

The Federal Clean Air Act prohibits the removal or rendering inoperative of
any device or element of design installed on or in a motor vehicle or motor
vehicle engine in compliance with Federal Emission Regulations by:

1. Any person prior to its sale and delivery to the ultimate purchaser, or

2. Any manufacturer or distributor after its sale and delivery to the ultimate
purchaser, or

3. Any person engaged in the business of repairing, servicing, selling,
leasing, or trading motor vehicles or motor vehicle engines following its
sale and delivery to the ultimate purchaser, or

4. Any person who operates a fleet of motor vehicles following its sale and
delivery to the ultimate purchaser.

16 General Information

ENGINES OTHER THAN VOLVO

For specific information on engines other than VOLVO, refer to the
engine vendor’s publications.

Noise Emissions

Volvo Trucks North America warrants to the first person who purchases this
vehicle for purposes other than resale and to each subsequent purchaser, that
this vehicle as manufactured by Volvo Trucks North America was designed,
built and equipped to conform, at the time it left the control of Volvo Trucks
North America, with all applicable U.S. EPA Noise Control Regulations.

This warranty covers this vehicle as designed, built and equipped by Volvo
Trucks North America, and is not limited to any particular part, component or
system of the vehicle manufactured by Volvo Trucks North America Defects
in design, assembly or in any part, component or system of the vehicle as
manufactured by Volvo Trucks North America, which, at the time it left the
control of Volvo Trucks North America caused noise emissions to exceed
Federal standards, are covered by this warranty for the life of the vehicle.

Noise Control System, Operator Inspection and Maintenance
Requirements

A Noise Control System Maintenance Log is located in this manual. This log
should be used to document all Noise Control System related maintenance,
whether the maintenance results from a specific noise control system
inspection, or a deficiency identified during another general maintenance
event.

If additional log space is needed, further entries may be added on a separate
sheet of paper. Store these additions with the main log to preserve a
comprehensive record. It is recommended that copies of all noise emissions
related maintenance invoices be retained.

The following Noise Control System inspection and maintenance instructions
contain suggested maintenance intervals. These intervals may need adjustment
in order to best accommodate the specific vehicle usage. The following
instructions only concern Noise Emissions related items and do not address or
modify any general vehicle maintenance requirements.

The following elements make up the Noise Control System:

앫 Noise Shielding and Insulation Devices

앫 Cooling System

앫 Exhaust System/DPF System

앫 Air Intake/Air Induction System

앫 Engine Control, EGR and Fuel Systems

General Information 17

Tampering with Noise Control System

Federal law prohibits the following acts or the causing thereof:

(1) The removal or rendering inoperative by any person, other than for
purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use;

or

(2) the use of the vehicle after such device or element of design has been
removed or rendered inoperative by any person.

Among the acts that constitute tampering are the acts listed below:

앫 Removal, or rendering inoperative, of any exhaust components, including

mufflers, heavy or double-wall exhaust tubing, flexible tubing or exhaust
pipe clamping.

앫 Removal, or rendering inoperative, of the temperature-modulated cooling

fan system.

앫 Removal of the cooling fan shroud.

앫 Removal, or rendering inoperative, of the air cleaner or air intake in-line

silencer.

앫 Removal of the sound deadening material from the hood or cab tunnel.

앫 Removal, or rendering inoperative, of the engine speed governor so as to

allow engine speed to exceed the manufacturer's specifications.

앫 Removal of splash shields located inside the wheel housings.

앫 Removal of engine block shields.

앫 Removal of engine crankcase shields or insulation.

앫 Removal of insulated rocker arm covers.

앫 Removal of transmission noise shields.

Noise Shielding and Insulation Devices

Maintenance

Ensure sound shielding and insulating devices are intact. Inspect components
for damage. Primary system components requiring noise related inspection
include the hood, engine compartment insulating materials (including hood
insulation, bulkhead insulation, doghouse insulation, etc.) splash shields, cab
skirts, fender shields, and body panels. Inspect all related fasteners, brackets,
and clamps for damage and tightness.

18 General Information

Regulatory Compliance

Acts that constitute tampering with the Noise Shielding and Insulation
Devices:

Removing or rendering inoperative the engine and/or transmission noise
deadening panels, shields or insulating materials.

Removing or rendering inoperative the cab-tunnel or hood noise insulating
materials.

Removing or rendering inoperative any vehicle body mounted sound
insulation components and/or shields (cab or fender shields, skirts, wheel
housing splash shields, etc.).

Cooling System

DO NOT work near the fan with the engine 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 seriously injured.

Maintenance

Visually inspect cooling system components for damage, and/or
misalignment.

Primary system components requiring noise related inspection include fan
blades, fan clutch, fan shroud, fan ring, and recirculation shields. Check fan
blades, fan ring, fan shroud, belt tensioner and recirculation shields for any
damage. Verify that fan blades clear the fan ring. Inspect all related fasteners,
brackets, and clamps for damage and tightness. Confirm operation of
temperature modulated fan clutch.

Regulatory Compliance

Acts that constitute tampering with the Cooling System:

Removing or rendering inoperative cooling system components (such as the
temperature modulated fan clutch, fan shroud, fan ring, recirculation shields,
etc.).

General Information 19

Exhaust System

Hot engine! Avoid all movable parts or hot engine parts, exhaust gases,
and/or fluids. A hot engine, exhaust, and/or fluids can cause burns.

Maintenance

Make sure the exhaust system is intact. Inspect for damage, misalignment and/
or leakage. Primary system components requiring noise related inspection
include exhaust manifold, turbocharger, and all exhaust system (rigid and
flexible) piping. Closely check the system for exhaust leaks. Special attention
should be given to all welds, seams, gaskets, support points, clamps, couplings
and connections.

Inspect all exhaust system fasteners, brackets, and clamps for damage and
tightness.

Regulatory Compliance

Acts that constitute tampering with the Exhaust System:

Removing or rendering inoperative exhaust system components (such as the
pipes, clamps, etc.).

Air Intake/Air Induction System

Maintenance

Make sure the air intake system is intact. Inspect components for damage,
misalignment and/or leakage. Primary system components requiring noise
related inspection include the air cleaner housing, air cleaner element,
turbocharger, charge air cooler and intake manifold.

Also inspect all ducts, pipes, hoses, tubing and elbows used to interconnect the
system. Special attention should be given to all welds, seams, gaskets, support
points, clamps, couplings and connections.

Inspect all intake system fasteners, brackets, and clamps for damage and
tightness.

Regulatory Compliance

Acts that constitute tampering with the Air Intake/Air Induction System:

Removing or rendering inoperative air intake/induction system components
(filter, filter housings, ducts, etc.).

20 General Information

Engine Control, EGR and Fuel Systems

Acts that constitute tampering with Engine Control, EGR and Fuel Systems:

Removing rendering inoperative, or modifying the engine control system such
as the ECU, EGR system components, or fuel system components, in order to
allow the engine to operate outside of the manufacturer's specifications is not
allowed and violates both warranty and legislation.

Noise Control Log

NOISE CONTROL SYSTEM MAINTENANCE LOG

DATE MILEAGE

MAINTENANCE

PERFORMED

MAINTENANCE

FAC ILITY

General Information 21

LABEL INFORMATION

VT Shown, VN and VHD Similar

1. Transmission Type and Gear
Pattern This information is

located in the visor.

2. VIN/GAWR Located in the
door frame “B” pillar.

3. VIN/Major Components
Located in the door frame “B”
pillar.

4. Vehicle Noise Emission
Located in the door frame “B”
pillar.

22 General Information

FUSE AND RELAY LOCATION

Always replace fuses and circuit breakers with the same current/
amperage. Increasing fuse or circuit breaker rating may result in
electrical circuit overheating and possible fire.

On sleeper models equipped with fluorescent lighting, there is a 3 AMP
maximum fuse located in the lighting fixture.

General Information 23

The fuse relay panel is located under the top cover of the dash board. The
vehicle has an electrical center located in the middle of the dash under the top
cover. Since the function of some fuses or relays may change for the vehicle
application, refer to the list of functions that is attached beneath each panel.

VN Fuse and Relay Center

VHD Fuse and Relay Center

24 Safety Information

SAFETY INFORMATION

PROPER MAINTENANCE PROCEDURE

Before working on a vehicle, set the parking brakes, place the transmission
in neutral, and chock the wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal injury or death.

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.

Never operate the engine in an area where hydrocarbon vapors (gasoline,
for example) are present or are suspected to be present. Hydrocarbon vapors
can enter the air intake and over speed the engine, causing severe engine
damage and/or an explosion and fire. Serious personal injury or death
could occur.

Never try to operate or work on this vehicle while under the influence of
alcohol. Your reflexes can be affected by even a small amount of alcohol.
Drinking and operating this vehicle can lead to an accident, causing serious
personal injury or death.

DO NOT attempt to repair or service this vehicle without having
sufficient training, correct service literature and the proper tools. Failure
to follow this could lead to personal injury or making your vehicle unsafe.

Diesel engine exhaust and some of its constituents are known to the state
of California to cause cancer, birth defects and other reproductive harm.

Safety Information 25

During Maintenance

Remove key from ignition while working on vehicle or engine.

DO NOT allow unauthorized personnel on, around or in the vehicle when
maintenance or repair is being performed.

앫 When operating the engine in an enclosed area, vent the exhaust to the

outside.

앫 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
ensure that the wheels are adequately chocked to prevent any forward
and/or rearward movement.

앫 DO NOT use combustible substances in or around the engine either

during repair or maintenance or when running the engine.

앫 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 required by the job conditions, such as protective glasses,
hearing protection, etc.

앫 Make certain that all protective covers and guards are in place and

properly secured.

앫 Never put maintenance fluids into glass containers since glass containers

can break.

앫 Report all problems in a timely manner before they threaten the safety of

operating the vehicle.

앫 DO NOT work on the engine while it is running.

앫 Make sure protective locks and covers are in their proper place.

앫 DO NOT use high amperage electronic starting devices for jump-starting

the engine. Rely on conventional battery charging for charging the
batteries or jump-start with the help of a start battery.

앫 DO NOT attempt repairs you do not understand. If you do not have the

proper tools/knowledge to perform the repairs correctly, Volvo
recommends contacting your nearest Volvo Truck dealer for all necessary
repairs.

앫 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 over speed on
start-up.

앫 Start the engine only from the driver seat. Never operate the starter motor

across the starter terminals or the batteries as this could bypass the engine
neutral-start system as well as causing damage to the electrical or
electronic systems.

26 Safety Information

Compressed Air and Water

Compressed air can cause serious personal injury. 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 200 kPa (30 psi) for cleaning purposes.

Asbestos Information

The Volvo engine and replacement parts for it shipped from the factory are
asbestos 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 asbestos fibers can create serious health risks, including death.

Fluid Penetration

Always use a piece of paper or cardboard when checking for a leak.
Escaping 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, immediate treatment must be administered by a doctor
familiar with this type of injury.

INJURY PREVENTION

Burn Prevention

Engine Parts

Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot
engine and/or fluid can cause serious burns.