Volvo FM, FH, NH, FL, NL Service Manual

Volvo Truck Corporation

Göteborg, Sweden

Discard previousService Bulletin 175–09 from 8.05. Changes are marked with a bar (I) in the margin.

Lubrication service and oil changes

Service Bulletin

Trucks

Date Group No. Release Page

12.05 175 09 18 1(47)

Lubrication service and oil changes

FM, FH, NH, FL, NL

T1006282

This service bulletin contains information on:

Service intervals

•

Oil and fluid volumes

•

Oil grade and viscosity

•

Filters and filter inserts

•

Charge regulator

•

Chassis lubrication, cab lubrication and grease quality

•

Drive belts (multiple grooved belts)

•

Air drier

•

Note: For service intervals for South America, see Service Bulletin 175 48 Note: For service intervals for the USA, please refer to Service Bulletins 175 001,

175 60 and 175 61.

ENG18795 English

20041386

Printed in Sweden

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 2(47)

Lubrication service and oil changes

Contents

“Engine” page 3

“Definitions” page 3 “Oil change volumes” page 6 “Oil filter” page 6 “Engine oil, change intervals” page 7 “Fuel filter change” page 18 “Filter for fuel tank ventilation” page 18 “Filter insert, air cleaner” page 18 “Particulate filter, CRT” page 18 “Mechanical compressor” page 18 “Coolant” page 19 “Drive belts” page 20 “Valves and unit injectors, adjustment” page 20

“Gas engine” page 20 “Charge regulator” page 21 “Clutch” page 21 “Gearbox” page 21

“1a. Volvo manufactured manual gearboxes” page 21 “1b. ZF manufactured manual gearboxes” page 25 “1c. Eaton manufactured manual gearboxes” page 26 “2a. Volvo manufactured automatic transmissions” page 27 “2b. Allison manufactured automatic transmissions” page 27

“Rear axle” page 29

“1a. Heavy rear axles” page 29 “1b. Light rear axles.” page 32 “1c. Other rear axles” page 33

“Driving front axle” page 34 “Transfer case” page 35 “Power take off (flywheel fitted)” page 37 “Hydraulic retarder” page 38 “Propeller shaft lubrication” page 39 “Power steering, Steerable pusher axle, Bogie lift, Hub, Cab tilt pump” page 41 “Brakes” page 41 “Chassis lubrication” page 41 “Cab” page 44 “Volvo oils and fluids” page 45

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 3(47)

Engine

Definitions

English terms have been used for some of the definitions that follow. This is international. Each term has, however an explanation in the language of the document.

Emissions classes

Euro 1 corresponds to EC93

•

Euro 2 corresponds to EC96, ECPT5 and ECPT6

•

Euro 3 corresponds to EC99, EC01 and ECPT4

•

Transport cycle

Typical construction site superstructure?1?

Yes No

Average distance between loading and unloading > 50 km and < 20% driving in a city environment and annual mileage >100000 km?

Construction sites

Includes timber trucks, tippers, dumpers, load exchangers, concrete mixers,waste compressors and special vehicles.

No Yes

Distribution Long distance driving

Engine Operating Conditions (EOC)

the engine operating conditions (EOC) describe the degree of engine load.

The different load levels are:

Light (L)

•

Medium (M)

•

Heavy (H)

•

Severe (S)

•

Very severe (VS)

•

Very severe+ (VS+)

•

The abbreviations named above are used in the EOC table.

Gross weight

Gross weight =

(combination) ton

Technical/Legal gross weight

Topography

Flat (F)

Uphill and downhill stretches with:

gradients >3% for up to 1% of total mileage.

•

Maximum gradients 8%.

•

T1008466

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 4(47)

Predominantly flat (PF)

Uphill and downhill stretches with:

gradients >3% for up to 20% of total mileage.

•

gradients >6% for up to 1% of total mileage.

•

Maximum gradients 16%.

•

T1008403

Hilly (H)

Uphill and downhill stretches with:

gradients >3% for up to 35% of total mileage.

•

gradients >6% for up to 10% of total mileage.

•

gradients >9% for up to 1% of total mileage.

•

Maximum gradients 20%.

•

Very Hilly (VH)

Typically mines, building sites etc

Abbreviations in brackets are used in the EOC table.

T1008404

T9008082

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 5(47)

Warranty

The warranty is not valid if Volvo Truck Corporation can show that it is likely that the material defects or incorrect operation, for which the warranty has been invoked, is the result of:

The vehicle not being driven in accordance with the

•

applicable Volvo Truck Corporation instructions, e.g. that the stipulated warranty, basic or full servicing has not been carried out at the correct time and/or running hours interval (a service that has not been registered by Volvo Truck Corporation or recorded in this booklet is considered not to have been performed, unless absolute proof can be shown).

Other parts than original parts from Volvo Truck

•

Corporation have been used. Other oils, greases or coolant fluids than those

•

recommended by Volvo Truck Corporation have been used.

The above text is only an extract from the Warranty booklet. Refer to the Warranty booklet forcomplete warranty terms, conditions and requirements.

Oil grade

VDS, VDS-2, VDS-3 alternatively API CF, CF-4, CG-4, CH-4, CI-4 or ACEA E2, E3, E4, E5

Viscosity

The viscosity is selected in accordance with the table. Temperature values refer to constant air temperatures.

1) Only VDS-2 or VDS-3 oils. When using 10W/30, fuel consumption can be

lower than when using 15W/40. Note however the temperature interval recommended for 10W/30.

Note that a combination of several of the above named qualities is required in some cases.

Note: Extra oil additives are not to be used. This includes engine and metal treatment additives added to the engine oil.

T1008235

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 6(47)

Oil change volumes

Engine type

D4 12 3,8 TD61, TD63 17 D6A, D6B 19,5 G6A 17 G6B TD71, TD73, D7A, D7B D7C D9A D9A OILS-ST 33 TD102, TD103, D10A, D10B 34,5 10 TD122, TD123 36,5 12 D12A 36 8 D12A, FL 36 6 D12C,D12D OILS-PL, D12F OILS-PL,

D12D OILS-ST D12D OILS-STR 38 6

Oil change volume in litres, incl.

approx. volume for oil filter.

19,5 6,5 20,5 6,5 19,5 6,5

28 6

33 8

Oil volume in litres between

dipstick Max-Min

5 5 5

D12C, D12D; construction site vehicle 38 6 D13A OILS-PL 33 8 D13A OILS-ST 37 6 TD162, TD163 D16A D16B D16C

47 15 42 10 42 9

Oil filter

The by-pass and full flow filter should be replaced at each oil change.

Use only Volvo original oil filters.

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 7(47)

Engine oil, change intervals

Service intervals: First oil and filter change is at the warranty service after

10,000 km or 4 weeks, whichever occurs first. Except all vehicles manufacturedin Europe.

Limits to the tables on the following pages

Definition of “Other oil grade” on the following pages:

•

Oils which meet at least one of the following ACEA E2, E3, E4, E5; API CF, CF-4, CG–4, CH-4, CI-4.

D13A engine:

•

Oil change intervals for the D13A engine must not

•

exceed 12 months. If the sulphur content in the fuel exceeds 0.05 per

•

cent by weight, the oil change interval should be reduced to 2/3 taking into account the distance driven, engine running hours and calendar time.

If the sulphur content in the fuel exceeds 0.5 per

•

cent by weight, the oil change interval should be reduced to 1/3 taking into account the distance driven, engine running hours and calendar time.

Note: These sulphur level limitations and oil change

intervals can also be applied for other engines,

although this is not mandatory. This applies irrespective of mileage, engine hours, calendar period or amount of fuel consumed. Fuels with extremely low sulphur content, such as environmentally classed fuels, do not permit the service interval to be extended.

Other engines:

•

No oil change interval is allowed to exceed 6 months.

If the sulphur content in the fuel exceeds 0.5 percentage by weight, the oil change interval

should be halved. This applies irrespective of mileage, engine hours, calendar period or amount of fuel consumed. Fuels with extremely low sulphur content, such as environmentally classed fuels, do not permit the service interval to be extended.

Full flow filter, longlife, with part number 478736 should

•

be used if the oil change interval exceeds 30,000 km. All 16 litre engines must use filter 478736 irrespective of oil change interval.

Interval tables

“TD61 TD63 TD71 TD73 ” page 8 “TD102, TD122, TD162” page 8 “TD103, TD123, TD163” page 8 “D4 D6A D7 D10 D12A D12C D16A D16B” page 8 “D6B Euro 2/Euro 3, D7C Euro 3” page 9

“D9A” page 12 “D12D Euro2/Euro3” page 13 “D12F EM JPN04” page 14 “D13A Euro3” page 16 “D16C Euro3” page 17

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 8(47)

TD61 TD63 TD71 TD73

Engine type Oil grade Max mileage in km

15 000 20 000 25 000 30 000 40 000 45 000 VDS-2/3 X VDS XTD61, TD63, TD71,

TD73

Other oil grade

TD102, TD122, TD162

Engine type Oil grade Max mileage in km

15 000 20 000 25 000 30 000 40 000 45 000 VDS-2/3 X VDS XTD102, TD122,

TD162

Other oil grade

TD103, TD123, TD163

Engine type Oil grade Max mileage in km

15 000 20 000 25 000 30 000 40 000 45 000

Max period,

months

Max period,

months

Max period,

months

VDS-2/3 X

TD103, TD123, TD163

VDS Other oil

grade

D4 D6A D7 D10 D12A D12C D16A D16B

Engine type D4, D6A, D7A/B D7C Eu2 (FM) D10, D12 (FL) Transport cycle

VDS-3/ VDS-2

VDS

Other oil grade

Whichever occurs first

Mileage, max (km) Fuelconsumed, max (litres)

- -

25 000 40 000

20 000 20 000 30 000 30 000

15 000 15 000 15 000 15 000

10 000 20 000 20 000

5 000 13 000 13 000

4 000 7 000 7 000

Long distance

driving

Other

40 000

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 9(47)

Engine type D12A Eu1 (FH) D12A/C Eu2/Eu3 (FM,

FH, NH)

Transport cycle Long

distance

driving

VDS-3/ VDS-2

VDS

Other oil grade

Whichever occurs first

D12C Eu2 (EC96), GCW<44 t: 25,000 litres

D16A Eu1 (EC93): 40,000 km

Mileage, max (km) Fuel consumed,

max (litres)

Mileage, max (km) Fuel consumed,

max (litres)

Mileage, max (km) Fuel consumed,

max (litres)

20 000 20 000 20 000

45 000 45 000 30 000 30 000 30 000 13 000 13 000 13 000 13 000 13 000 13 000

15 000 15 000 15 000 15 000 15 000 15 000

7 000 7 000 7 000 7 000 7 000 7 000

Other Long

distance

driving

45 000

Other Long

45 000 20 000 20 000 20 000

D6B Euro 2/Euro 3, D7C Euro 3

The following is a step by step description of how to read the tables below.

1. Go to row “Gross weight, combination” and select an appropriate column.

D16A, D16B

distance

driving

Other

40 000

30 000

2. Go to the next row in the selected column. This column can in turn be divided into several columns depending on the fuel consumption of the truck in question.

3. Select the column which corresponds to the average fuel consumption forthe vehicle.

4. This column will contain the values for the three oil qualities. Select the grade which is to be used and read off the “Mileage” and “Fuel consumed”, select the value which occurs first.

D6B Euro 2/Euro 3

Gross weight, combination Less than 15 000 kg Fuel consumption, average Less than or equal

to 25 litres/100 km

Oil grade VDS-3

plus ACEA E3

VDSorOther oil grade

Whichever occurs first

Note that the oil grade must comply with both VDS and ACEA E3

Mileage, max (km) Fuel consumed,

max (litres)

Mileage, max (km) Fuel consumed,

max (litres)

Mileage, max (km) Fuel consumed,

max (litres)

40 000 32 000 25 000

30 000 25 000 20 000Oil grade VDS-2orVDS

15 000 15 000 15 000

4 000 4 000 4 000

Less than or equal to 30litres/100 km

8 000 8 000

6 000 6 000

More than 30 litres/100 km

Gross weight, combination Less than 19,000 kg More than19,000 kg Fuel consumption, average Less thanor equal

to 30 litres/100 km

Oil grade VDS-3

Mileage, max (km) Fuelconsumed, max

(litres)

40 000 25 000 25 000

8 000 8 000 8 000

Morethan 30 litres/100kmIndependent of fuel

consumption

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 10(47)

Gross weight, combination Less than 19,000 kg More than 19,000 kg Fuel consumption, average Less than or equal

to 30litres/100 km

plus ACEA E3

VDSorOther oil grade

Whichever occurs first

Note that the oil grade must comply with both VDS and ACEA E3

Mileage, max (km) Fuelconsumed, max

(litres) Mileage, max (km) Fuelconsumed, max

(litres)

30 000 20 000 20 000Oil grade VDS-2orVDS

6 000 6 000 6 000

15 000 15 000 15 000

4 000 4 000 4 000

D7C Euro 3

Gross weight, combination Less than 18,000 kg Fuel consumption, average Less than or equal

to 25 litres/100 km

Oil grade VDS-3

Oil grade VDS-2orVDS plus ACEA E3

VDSorOther oil grade

Whichever occurs first

Note that the oil grade must comply with both VDS and ACEA E3

Mileage, max (km) Fuel consumed,

max (litres)

Mileage, max (km) Fuel consumed,

max (litres)

Mileage, max (km) Fuel consumed,

max (litres)

40 000 32 000 25 000

30 000 25 000 20 000

15 000 15 000 15 000 4 000 4 000 4 000

More than 30 litres/100kmIndependent of fuel

consumption

Less than or equal to 30 litres/100 km

More than 30 litres/100 km

8 000 8 000

6 000 6 000

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 11(47)

Gross weight, combination Less than 26,000 kg More than 26,000

Fuel consumption, average Less than or equal to

30 litres/100 km

Oil grade VDS-3

Oil grade VDS-2orVDS plus ACEA E3

VDSorOther oil grade

Whichever occurs first

Note that the oil grade must comply with both VDS and ACEA E3

Mileage, max (km)

Fuel consumed, max (litres)

Mileage, max (km)

Fuel consumed, max (litres)

Mileage, max (km)

Fuel consumed, max (litres)

40 000 25 000 25 000

8 000 8 000 8 000

30 000 20 000 20 000

6 000 6 000 6 000

15 000 15 000 15 000

4 000 4 000 4 000

More than 30 litres/100 km

Independent of fuel consumption

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 12(47)

D9A

For definitions and abbreviations see “Definitions” page 3.

Engine Operating Conditions (EOC)

Transport cycle

Long distance driving Distribution

regional

Distribution

town

Construction sites

GCW To-

F PF H F H H H VH

≤44 45-65 ≤29 30-44 45–65 ≤29 ≥30 ≤44 ≥45

pography

EOC M

Includes timber trucks, tippers, dumpers, load exchangers, concrete mixers,waste compressors and special vehicles.

Only 4x2/6x2, without power take off, max 90 kph

H H S M

H S S VS S VS VS+

Oil change interval

EOC M H S VS VS+ Maximum permitted fuel consumption

≤ 35 ≤ 44

(l/100 km)

Mileage (km) / time (hours) NB! No oil change interval is allowed to exceed 6 months. Oil grade VDS-3 60000/- 45000/600 30000/400 15000/4001-/400 Oil grade VDS-2 40000/- 30000/400 20000/300 10000/3002-/300 Oil grade VDS /

20000/- 15000/200 10000/150 5000/150

Other oil grade

For waste collection, mine operation, airport service etc, engine hours (hours) can be used instead.

Maximum permitted fuel consumption 15 000 litres (37.5 litres/hour).

Maximum permitted fuel consumption 10 000 litres (33.3 litres/hour).

Maximum permitted fuel consumption 5 000 litres (33.3 litres/hour).

≤ 57

≤ 100

-/150

Preventive maintenance

EOC M H S VS VS+

km/max. months H/max.

months Full service -/12 Basic service 60000/6

Whichever occurs first.

45000/6

30000/6

15000/6

400/6

Valves and unit injectors, adjustment

EOC M H S VS VS+ Interval 200,000 km or every 12 months,

whichever occurs first¹

¹ The service interval shall be halved in the case of frequent driving at more than 90km/h

100,000 km or every 6 months, whichever

occurs first

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 13(47)

D12D Euro2/Euro3

For definitions and abbreviations see “Definitions” page 3.

Engine Operating Conditions (EOC)

Transport cycle

GCW

To-

Long distance driving

≤ 44

45 - 68 ≥ 69 ≤ 44 45 –68≥69 ≤ 32 ≥ 33 ≤ 68 ≥ 69

F PF H F H H H VH

Distribution,

regional

Distribution,

Town

Construction sites

pography

EOC L

Includes timber trucks, tippers, dumpers, load exchangers, concrete mixers,waste compressors and special vehicles.

Only 4x2/6x2, without power take off, max 90 kph, D12DEuro3, Europe

Only 4x2/6x2, without power take off, max 90 kph

H H S VS H S VS S VS S VS VS+

Oil change interval

EOC L M H S VS VS + Maximum permitted fuel

consumption (l/100 km)

Mileage (km) / time (hours) NB! No oil change interval is allowed to exceed 6 months. Oil grade VDS-3 900001/- 75000/- 60000/750 45000/600 20000/6002-/600 Oil grade VDS-2 60000/- 50000/- 40000/500 30000/400 15000/4003-/400 Oil grade VDS / Other oil

grades

For waste collection, mine operation, airport service etc, engine hours (hours) can be used instead.

Can be extended to 100,000 km if gross weight never exceeds 36 tons with other conditions unchanged and VDS-3 oil used.

Maximum permitted fuel consumption 25 000 litres (41.7 litres/hour).

Maximum permitted fuel consumption 16 000 litres (40 litres/hour).

Maximum permitted fuel consumption 8 000 litres (40 litres/hour).

≤ 33 ≤ 39 ≤ 46 ≤ 59 ≤ 120

30000/- 25000/- 20000/250 15000/200 10000/2004-/200

Preventive maintenance

EOC L M H S VS VS+

km/max. months H/max.

months Full service —/12 Basic service 90000/6

Whichever occurs first.

75000/6

60000/6

45000/6

20000/6

600/6

Valves and unit injectors, adjustment

EOC M H S VS VS+ Interval

D12D 340–460

Interval D12D 500

¹ The service interval shall be halved in the case of frequent driving at more than 90km/h

400,000 km or every 24 months,

whichever occurs first¹

200,000 km or every 12 months,

whichever occurs first¹

200,000 km or every

12 months, whichever

occurs first

100,000 km or every 6 months, whichever

occurs first

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 14(47)

D12F EM JPN04

For definitions and abbreviations see “Definitions” page 3.

Engine Operating Conditions (EOC)

Transport cycle

GCW To-

Long distance driving

≤ 44 45 - 68 ≥ 69 ≤ 32 32–44 45–68 ≤ 32 32–44 ≤ 44 ≤ 32 33–44 45–68 PF H PF H H H H VH

Distribution,

regional

Distribution,

Town

Construction sites

pography

EOC M

Includes timber trucks, tippers, dumpers, load exchangers, concrete mixers,waste compressors and special vehicles.

Only 4x2/6x2, without power take off, max 90 kph

Max. 90 km/h

VS3M H S S VS VS H S VS VS+

Oil change interval

EOC M H S VS VS+ Maximum permitted fuel consumption

(l/100km)

Mileage (km) / time (hours) NB! No oil change interval is allowed to exceed 6 months.

Oil grade VDS-3

Oil grade VDS-2 35000/450 25000/350 20000/300 10000/3003-/300 Oil grade VDS / Other oil grades 20000/300 15000/250 10000/200 7500/200

For waste collection, mine operation, airport service etc, engine hours (hours) can be used instead.

D12 F can be fitted with DPF-filter. In this case VDS-3 LSA quality oil must be used. VDS–3 LSA is VDS-3 oil with low sulphate content, max

1.1%. The same interval as for VDS-3 oils applies, as shown in the abovetable.

Maximum permitted fuel consumption 15 000 litres (37.5 litres/hour).

Maximum permitted fuel consumption 12 000 litres (40 litres/hour).

Maximum permitted fuel consumption 8 000 litres (40 litres/hour).

≤ 39 ≤ 50 ≤ 64 ≤ 120

50000/650 40000/500 30000/400 15000/4002-/400

-/200

Preventive maintenance

EOC M H S VS VS+

km/max. months H/max.

months Full service -/12 Basic service 50000/6

Whichever occurs first.

40000/6

30000/6

15000/6

400/6

Valves and unit injectors, adjustment

EOC M H S VS VS+ Interval

D12F 390–500

200,000 km or every 12 months,

whichever occurs first¹

100,000 km or every 6 months, whichever

occurs first

¹ The service interval shall be halved in the case of frequent driving at more than 90km/h

EGR pipe, clean

Service interval 200,000 km or every 24 months, whichever occurs first

Volvo Truck Corporation Date Group No. Release Page Service Bulletin 12.05 175 09 18 15(47)

Particulate filter, DPF, clean

Service interval Every 12 months

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