Volvo D13F, D11F User Manual

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OPERATOR'S MANUAL

VEHICLE MAINTENANCE VN,VHD

Volvo d11f and d13f engines

Volvo Trucks. Driving Success.R

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

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 (888) 327-4236, by writing to NHTSA, U.S. Department of Transportation, Washington, DC 20590, by TTY at 1 (800) 424-9153, 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

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:

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.

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:

Aftertreatment Fuel Injector (AFI)

AFI Shutoff Valve

Discharge Recirculation Valve

Pre-Catalyst Temp. Sensor

Post-Catalyst Temp. Sensor

Downstream DPF Temp. Sensor

Differential Pressure Sensor

m.Sensors:

Engine Timing/Speed (flywheel)

Engine Position (camshaft)

Temperature — Coolant

Temperature — Inlet Manifold Air

Pressure — Boost Air

Humidity

EGR Temperature

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, (336) 393-2000. 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 (336) 393-2000

12

General Information

CALIFORNIA EMISSION CONTROL SYSTEMS SERVICE RECORD

CALIFORNIA EMISSION CONTROL SYSTEMS SERVICE RECORD

DATE

KM\MILES

SERVICE PERFORMED

SERVICED BY

 

 

 

 

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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:

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.

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:

Aftertreatment Fuel Injector (AFI)

AFI Shutoff Valve

Discharge Recirculation Valve

Pre-Catalyst Temp. Sensor

Post-Catalyst Temp. Sensor

Downstream DPF Temp. Sensor

Differential Pressure Sensor

m.Sensors:

Engine Timing/Speed (flywheel)

Engine Position (camshaft)

Temperature — Coolant

Temperature — Inlet Manifold Air

Pressure — Boost Air

Humidity

EGR Temperature

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:

Noise Shielding and Insulation Devices

Cooling System

Exhaust System/DPF System

Air Intake/Air Induction System

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:

Removal, or rendering inoperative, of any exhaust components, including mufflers, heavy or double-wall exhaust tubing, flexible tubing or exhaust pipe clamping.

Removal, or rendering inoperative, of the temperature-modulated cooling fan system.

Removal of the cooling fan shroud.

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

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

Removal, or rendering inoperative, of the engine speed governor so as to allow engine speed to exceed the manufacturer's specifications.

Removal of splash shields located inside the wheel housings.

Removal of engine block shields.

Removal of engine crankcase shields or insulation.

Removal of insulated rocker arm covers.

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.

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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.).

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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

MAINTENANCE

PERFORMED

FACILITY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

General Information

21

LABEL INFORMATION

VT Shown, VN and VHD Similar

1. Transmission Type and Gear

3.

VIN/Major Components

Pattern This information is

 

Located in the door frame “B”

located in the visor.

 

pillar.

2. VIN/GAWR Located in the

4.

Vehicle Noise Emission

door frame “B” pillar.

 

Located in the door frame “B”

 

 

pillar.

 

 

 

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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

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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.

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

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.

DO NOT use combustible substances in or around the engine either during repair or maintenance or when running the engine.

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.

Make certain that all protective covers and guards are in place and properly secured.

Never put maintenance fluids into glass containers since glass containers can break.

Report all problems in a timely manner before they threaten the safety of operating the vehicle.

DO NOT work on the engine while it is running.

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

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.

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.

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.

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.

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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.

Safety Information

27

 

 

 

 

DO NOT raise the engine hood if you see or hear steam or coolant escaping from the engine compartment. Wait until steam or coolant cannot be seen or heard any longer before raising the hood.

DO NOT remove the coolant fill cap if the coolant in the surge tank is boiling. Also, do not remove the cap while the engine and radiator are still hot. Scalding fluid and steam may be blown out under pressure if the cap is taken off too soon, which can cause personal injury and damage to engine components.

DO NOT touch any part of the engine while it is hot. Allow the engine to cool before any repair or maintenance is performed on the engine.

Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or related items are disconnected or removed.

Coolant

Coolant may be combustible. Coolant leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up coolant spills immediately.

28

Safety Information

To prevent personal injury, do not climb up on the engine to remove the filler cap. Use a suitable, properly positioned ladder to reach the cap. At normal operating temperature, the engine coolant is very hot and under pressure. If pressure is relieved rapidly in a hot cooling system, the hot coolant can turn into steam. Any contact with hot coolant or steam can cause severe burns. The radiator and all heating system and radiator lines and hoses contain hot coolant.

Verify coolant level only by the markings on the expansion tank. Open the filler cap only after the engine is stopped and cooled down. Remove the filler cap slowly to relieve pressure.

Oils

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

Hot oil can cause severe burns. DO NOT allow hot oil to contact the skin. When changing oil, wear protective gloves.

Batteries

Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Battery electrolyte contains acid and can cause injury. Avoid contact with the skin and eyes. Wash hands after touching batteries and connectors. Use of gloves is recommended. Always wear protective glasses when working with batteries.

Safety Information

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Speed Restrictive Tires

Operating a vehicle equipped with speed restrictive tires in excess of their stated rating may result in tread separation and/or blowout resulting in the loss of steering control and possible collision. Serious personal injury or death could occur. Always maintain proper air pressure and never exceed the tire ratings.

When a vehicle is equipped with speed restrictive tires, DO NOT operate the vehicle in excess of the indicated speeds. If your vehicle is equipped with such tires, the speed restrictions will be stated on the sidewall of the tires. The operator of this vehicle is urged to check the tires of the vehicle to determine if there are any limitations.

Fire or Explosion Prevention

The diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may over speed during start-up. Engine damage and severe injury and/or death from burns or explosion can occur.

Excessive heat may cause the pressurized components of the air conditioned system to explode. Some mixtures of R134a refrigerant can become combustible at elevated pressures. Never weld, solder, steam clean or use a gas torch near any part of the air conditioning system. Severe injury or death may occur from an explosion.

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Safety Information

 

 

 

 

DO NOT service any part of the fuel system while smoking or in the presence of flames, sparks or hot surfaces. Failure to follow these precautions can result in fire, which can cause serious injury or death.

DO NOT store fuel containers in the vehicle. They may leak, explode and cause or feed a fire. Empty or full, they present a hazard that may lead to burns in the event of a fire.

The engine should not be operated in an area where combustible gases are suspected to be in the air. These could be drawn into the engine through the engine air intake system and could cause the engine to over speed with possible serious damage to the engine and bodily injury or property damage.

Make provisions for shutting off the engine intake air or fuel supply to stop the engine if there is an over speed on start-up after performing repair or maintenance on it.

Contact your nearest Volvo Truck dealer for any necessary air conditioning testing or repairs.

All fuels, most lubricants and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes is extremely explosive. DO NOT smoke while refueling or when in a refueling area.

Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized personnel. Store oily rags or other flammable material in a protective container, in a safe place.

Remove all flammable material such as fuel, oil and other substances before they accumulate on the engine.

Safety Information

31

DO NOT expose the engine to flames, driving over burning ground.

DO NOT weld or flame cut on or around pipes or tubes that contain flammable fluids.

Exhaust heat shields may be installed to protect oil or fuel carrying lines and pipes from hot exhaust parts. To protect from pipe or seal failure, install heat shields correctly.

Provide adequate and proper waste oil disposal. Always dispose of waste liquids according to Federal and local regulations. Oil and fuel filters should be properly installed and housing covers tightened to the proper torque when being changed.

Starting Aids

DO NOT use ether or other combustible starting aids on any engine equipped with a preheater. If the engine is equipped with a preheater, introduction of ether or similar starting aids could cause a fire or explosion resulting in severe property damage, serious personal injury or death.

DO NOT use ether or other combustible starting aids on engines that have a heater element or other heating devices installed in the intake manifold for heating the intake air during cold-starts.

32

Safety Information

Fire Extinguisher

Anytime work is being done to the fuel system or any other area where flammable substances are being used, have a fire extinguisher available and know how to use it. Inspect and have it serviced as recommended on its instruction label.

Respiratory Hazard Prevention

Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose. Prolonged or excessive exposure may cause serious illness or death.

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

Always work in a well ventilated space if the engine needs to be running and use a hose to route the exhaust to the outside.

Poisonous Substances

Coolant is toxic; risk of poisoning.

DO NOT drink coolant. Use proper hand protection when handling. Keep coolant out of reach of children and animals. Failure to follow these precautions can cause serious illness or death.

Cooling system supplemental additive contains alkali. To prevent personal injury, avoid contact with the skin and eyes.

DO NOT drink coolant of any concentration.

Safety Information

33

Crushing or Cutting Prevention

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.

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.

Never attempt adjustments or repairs while the engine is running, see your authorized Volvo Truck dealer.

Inspect the fan blade assembly before service for cracks or loose mounting before starting the engine. Never stand alongside a rotating fan assembly, particularly at high fan speeds.

Wear protective glasses when striking objects to avoid injury to your eyes. Chips or other debris can fly off objects that are struck. Make sure no one can be injured by flying debris before striking any object.

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Safety Information

Climbing Up and Down

Always have three limbs (one foot and two hands or two feet and one hand) in contact with the vehicle at all times when entering or exiting the cab or the area behind the cab. Failure to follow this warning can result in serious personal injury or death.

DO NOT climb up on or jump off from the engine or stand on components that cannot support your weight. Use an adequate ladder or scaffolding, suitably situated.

DO NOT use top of engine or cowling ledge as foothold when reaching on top of cab. Clean steps, handholds and areas of the vehicle on which you will be working or are around. Refer to the Operator's Manual for proper entry and exit procedures.

Always use a three-point stance (two hands and one foot or one hand and two feet) whenever climbing up or down.

ENGINE DAMAGE PREVENTION

Before Starting the Engine

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.

Inspect engine for potential hazards. Make sure all protective guards and covers are properly installed if an engine needs to be started to make adjustments or checks. To help prevent an accident by moving parts, work carefully around them.

DO NOT disable or bypass automatic alarm/shutoff circuits. They are provided to prevent personal injury and engine damage.

Only properly trained and authorized Volvo Service Technicians may attempt repairs on this vehicle.

Safety Information

35

Engine Starting

DO NOT start the engine or move any of the controls or disengage the parking brake if the warning tag “DO NOT OPERATE” is attached to the ignition key or located on the dash. Check with the person who attached the tag before starting.

Make sure no one is working on or close to the engine or components driven by the engine before starting it. Always make an inspection of the engine before and after starting.

Diesel engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well-ventilated area, and if in an enclosed area, vent the exhaust to the outside.

Start the engine only from the driver seat in the cab. Never start the engine by shorting across the starter motor terminals or batteries to start the engine as this could bypass the engine neutral-start system as well as damage the electrical and electronic system. Always start the engine according to the required engine starting procedure described in this operator's manual to prevent major engine component damage and personal injury.

Starting Aids

DO NOT use ether or other combustible starting aids on any engine equipped with a preheater. If the engine is equipped with a preheater, introduction of ether or similar starting aids could cause a fire or explosion resulting in severe property damage, serious personal injury or death.

36

Safety Information

ELECTRIC SYSTEM DAMAGE PREVENTION

Electric and Electronic Systems

Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion.

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the flammable vapor mixture of hydrogen and oxygen to explode.

To prevent potential sparks from igniting combustible gases produced by some batteries, attach the negative (—) terminal last when hooking up and remove the negative terminal first after the engine has started. Check regularly around the engine and engine compartment for loose or frayed wires. Have all loose or frayed electrical wires tightened, repaired or replaced before operating the vehicle.

Grounding Practices

Proper grounding for vehicle and engine electrical and electronic systems is necessary for proper vehicle and engine performance and reliability. Improper grounding will result in uncontrolled and unreliable electrical paths.

Uncontrolled engine electrical circuit paths can result in damage to main bearings, crankshaft journals surfaces and aluminum components. Uncontrolled electrical circuit paths can also cause electrical noise which may degrade vehicle and radio performance.

Operating engines without the engine-to-frame ground strap installed can cause damage to the engine. To prevent electrical discharge damage, check to make sure the engine's electrical system has an engine-to-frame ground strap. All ground connections should be tight and free of corrosion.

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