Volvo Quality Service Manual
Volvo Truck Quality Manual
1 Introduction
1
2 Parking
2
3 General requirements
3
4
4 Loading / unloading operation
5
Transport by jockeys
6
5 Securing / lashing / support onboard carrier
7
6 Loading / unloading operation Lo/Lo
8
7 Damages
9
Quality audits
1
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Table of contents
1 Introduction 4
2 Parking 5
2.1 Parking requirements 5
2.2 Parking routines 5
2.3 Distances between parked vehicles 6
2.4 Slippery prevention 6
2.5 Snow & ice 6
3 General requirements 7
Trucks related
3.1 Tow / jump start 7
3.2 Starting with starting cables 8
3.3 Mechanical problems 10
3.4 Start the engine 10
3.5 Batteries 13
3.6 Central locking 15
3.7 Gearboxes 17
3.8 Ad Blue (Urea solution) 19
3.9 Air suspension 21
3.10 Airbag 22
Driver related
3.11 Clothing 22
3.12 Drawing / marking / attaching 22
3.13 Miscellaneous 24
3.14 Some driving advice 25
4 Loading / unloading operation Ro/Ro 26
4.1 Distances between stowed trucks 26
4.2 Preparation of ship / trailer 26
4.3 Driving behaviour in port area or terminal 27
4.4 Driving behaviour onboard ship 27
4.5 Parking routines onboard ship 28
4.6 Stowing onboard ship 28
4.7 Lashing / unlashing routine 29
4.8 General condition 29
4.9 Ramps and loading platform 29
4.10 Lashing equipment 30
4.11 Attachment of lashing sling 31
4.12 Lashing of trucks 31
5 Transport by jockeys 33
5.1 General 33
5.2 Driving behaviour 33
5.3 Mechanical problems 33
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6 Securing / lashing / support onboard carrier 34
6.1 Introduction to this chapter 34
6.2 Wheel chocks 34
6.3 Wheel lashings 34
6.4 Lashing on tyres 35
6.5 Lashing on rims 35
6.6 Lashing around the axles 35
6.7 Lashing around the rear stabilizer 34
6.8 Use of supports 34
6.9 Securing carrier ramps 37
6.10 Lashing 37
6.11 Dismounting of parts 38
7 Loading / unloading operation Lo/Lo 43
7.1 Introduction to this chapter 43
7.2 Lifting instructions 43
7.3 Lashing methods for trucks piggyback 45
8 Damages 46
9 Quality audits 46
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3
INTRODUCTION
1
These requirements are valid for all kind of distribution activities of Volvo Trucks including
loading/unloading as well as other types of handling performed in ports, stopovers or
terminals. The instruction applies to all Volvo Logistics contracted parties.
These requirements also apply for all other brands which are handled under the
responsibility of Risk Management Department.
These requirements are Volvo’s minimum demands.
Each transport company can issue their own requirements, but must be in accordance with
Volvo’s. If any kind of handling instruction are issued a copy must be sent to Volvo
Logistics Risk Management Dept.
Please note that these requirements do not in any way supersede the regulations
stipulated by various authorities.
Random inspections and planned audits will be made continuously within all areas,
terminals, ports, carriers, and vessels.
Detected remarks will be reported to the responsible persons at the contracted party.
The contracted party is responsible for ensuring that all involved personnel is notified and
aware of these requirements.
All product training for personnel should be stated in writing.
Training records must be maintained and updated, and to be handed
over to Volvo Logistics upon request.
The handling instruction provided by VLC will be updated on an
ongoing basis. Always search at Volvo Logistics website for the latest edition available
VOLVO LOGISTICS CORPORATION
Risk Management Department
http://www.volvo.com/logistics/global/en-gb
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2 Parking
2.1 Parking requirements
All parking areas and roadways:
• must be well separated from other activities
• must be free from any object that may damage the vehicles
• must be cleaned up regularly
• must be covered with hard surface, asphalt or similar
• must be well drained
• must be fenced, guarded and well litt
• must be equipped with an efficient drive-through protection to
prevent theft
• must have alarm system or camera surveillance
• must be pot hole free
• all vegetation must be systematically removed from the compounds and their
immediate surroundings
• must be divided into separate areas dedicated to :
Truck storage and truck loading / unloading
The trucks should be parked away from sources of emission that could contaminate them.
When parking in loadlines we recommend that all trucks are parked with the driver side
wheels on the marked line in order to get straight rows.
2.2 Parking routines
Make sure that;
• parking brake is in on-position
• transmission is in N position
• all windows, doors etc. are closed
• wiper blades are in rest position
• ignition and all electric devices are switched off
• electric main switch is in off-position
• key in ignition or according to respective yards routine
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2.3 Distances between parked vehicles
Minimum distances between parked trucks :
- Between sides 1 metre (40 inches)
- Between vehicles lengthwise minimum 30 cm (12 inches)
Driver’s door must be opened into an open space.
2.4 Slippery prevention
Avoid using stone chips for slippery prevention. Salt to be used with caution, avoid salt at
parking areas. Ports located in areas, requiring slippery prevention, must have valid and
updated routines for this. Used slippery prevention material such as sand must be cleaned
up as soon as the weather allows it.
2.5 Snow and ice
Snow on parking areas must be removed before the vehicles are parked. Snow to be taken
away with proper equipment. Rotating brushes or snow throwers are not to be used close
to the vehicles.
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3
General requirements
3.1 Tow/jump start
It is absolutely forbidden to use trucks aimed for distribution for towing or to jump-start a
non-starter. If the battery is low, use help-batteries or battery from a service car.
Non-starter should only be handled by authorized personnel and follow instructions.
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3.2 Starting with starting cables
1 Turn the ignition key to 0 position.
2 Make sure that the help start battery
has 24 V total voltage or 24 V system
voltage.
3 Switch the engine of the “assisting
vehicle” off, and make sure that the
vehicles do not touch one another.
4 Connect one of the clamps on the red
cable to the positive terminal on the help
battery. The positive pole is marked in
red, P or +.
5 Connect the other clamp on the red
cable to the positive terminal on the
battery of the vehicle that needs help.
The positive pole is marked in red, P
or +.
6 Connect one clamp on the black cable
to the negative terminal of the help
battery marked in blue, N or -.
7 Connect the other clamp on the black
cable to a place - an earth - some
distance from the battery of the vehicle
which needs help.
8 Start the engine of the “assisting
vehicle”. Let the engine run for some
minutes at a higher idle speed than
normal (about 1000 rpm).
9 Start the engine on the other vehicle.
10 Remove the clamp on the black cable
from the earth point.
11 Remove the clamp on the black cable
from the negative terminal on the help
battery.
12 Remove the red cable.
Do not use a start help unit as these can
supply extremely high voltages which can
damage control units
CAUTION
Note: After the truck has been started by using starting cables, the batteries should
be charged using a battery charger. It takes about 20 hours to fully charge a battery.
An alternator can never charge the battery to 100%; in favourable circumstances a
maximum level of 90% can be achieved. Refer to the “Electrical system” section in
the “Driver’s Manual, maintenance” for more information.
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Starting with starting cables, battery box at the rear
Always use another vehicle or other batteries
to help start the engine
The starting cables should be able to handle
1000 A for at least 30 seconds.
1 Turn the ignition key to 0 position.
2 Make sure that the help start battery
has 24 V total voltage or 24 V system
voltage.
3 Switch the engine of the “assisting
vehicle” off, and make sure that the
vehicles do not touch one another.
4 Connect one of the clamps on the red
cable to the positive terminal on the help
battery. The positive pole is marked in
red, P or +.
5 Connect the other clamp on the red
cable to the positive terminal on the
battery of the vehicle that needs help.
The positive pole is marked in red, P
or +.
6 Connect one clamp on the black cable
to the negative terminal of the help
battery marked in blue, N or -.
7 Connect the other clamp on the black
cable to a place - an earth - some
distance from the battery of the vehicle
which needs help.
8 Start the engine of the “assisting
vehicle”. Let the engine run for some
minutes at a higher idle speed than
normal (about 1000 rpm).
9 Start the engine on the other vehicle.
10 Remove the clamp on the black cable
from the earth point.
11 Remove the clamp on the black cable
from the negative terminal on the help
battery.
12 Remove the red cable.
Note: After the truck has been started by using
starting cables, the batteries should
be charged using a battery charger. It takes
about 20 hours to fully charge a battery.
An alternator can never charge the battery
to 100%; in favourable circumstances a
maximum level of 90% can be achieved.
Refer to the “Electrical system” section in
the “Driver’s Manual, maintenance” for
more information.
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Do not use a start help unit as these can
supply extremely high voltages which can
damage control units.
Batteries contain oxyhydrogen gas which
is very explosive. A spark, which can
ignite if you connect the starting cables
incorrectly, or if they are moved around
during the starting procedure, is
sufficient
for the battery to explode and cause
serious damage and injury. Batteries
contain sulphuric acid, which can cause
serious corrosion damage. If the acid
gets
in your eyes, skin or clothes, rinse with
large amounts of water. If the acid gets
in
your eyes, get medical attention at once.
Do not lean over the batteries.
CAUTION
WARNING
9
3.3 Mechanical problems
If a mechanical problem occurs during distribution at harbour or terminal
contact Volvo Action Service.
3.4 Start the engine
1 Turn on the main switch.
2 Check that
• the parking brake is applied
• the gearbox is in neutral
• the auxiliary brake is in position 0
3 Turn the starter key to the drive position
Note: If the key is turned straight from
the off position to the start position on
trucks with D13 engines, there is a delay of
about one second before the starter motor is
activated. During this time the starter motor
shows no response as it is activated via
EMS. When the key is turned from ignition
position to start, there is no delay.
4 The display shows the engine oil level.
If the engine has been running during the
last 20 minutes, nothing is shown. The value
shown under the graph is the difference
between the engine max and min oil volumes.
5 If the truck has air bags, the symbol for
this is shown on the display.
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6 Check that all the instrument panel lamps
are working
7 If the engine has pre-heating, turn the start
key to pre-heating position and release the
key
8 Wait until the pre-heating symbol goes out.
9 Start the engine
Run the starter motor by holding the key
in the start position for a maximum of
30 seconds. If the engine has not started
within 30 seconds: Turn the key to the radio
position and wait for 15 seconds before
trying to start again.
The following applies for D13: Run the
starter motor by holding the key in the start
position. If the engine does not start, the
starting attempt will be automatically shut
off after 15 seconds. A new attempt can be
made by turning the key back to 0 position
and then again to start position.
Note: The starter motors on the D12 and
D13 engines have automatic overheating
protection.
If the overheating protection cuts in on trucks
with a D12 engine, the starter motor must
cool down for 3 -15 minutes before a new
attempt can be made.
If the overheating protection cuts in on trucks
with a D13 engine, a message is displayed to
verify this. The message shows how long the
starter motor must be allowed to cool before
it will be possible to try to start the truck
again, usually 10–15 minutes.
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10 Hold down the brake pedal for a few
seconds to enable the cruise control
The air suspension is activated first after
the parking brake is released or if the air
suspension control box is used.
If the temperature of the coolant is below
50 C when the engine is switched on, the
engine speed will be limited to 1000 rpm for
15 seconds
Warming up
Warm the engine up by driving with low
engine speed rather than running the
engine while stationary. Avoid revving up
excessively and high engine speed.
After starting let the clutch out in order to
warm up the gearbox. The oil pump in the
gearbox will begin working and will quickly
attain working temperature.
Note: It is especially important that the
gearbox is warmed up if the outside
temperature is below 0 C.
WARNING
Do not use start gas. An explosion can
cause considerable damage.
Blocking valve
If the pressure in the braking system is too
low, for example if the truck has been parked
for a long period of time, the blocking valve
must be pushed in for the parking brake to be
released. Before the blocking valve can be
pushed in the pressure in the braking system
must exceed about 5 bar.
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3.5 Batteries
Before start the vehicle = reconnect the batteries
Verify that ignition and main switches are placed in off mode before re-connecting batteries
Battery boxes found at side of the frame or rear end of frame. Re-connect Press down to bottom
Important!! Press down the cable Lock secure Correct position
Always disconnect the electrical main switch when parking the truck
Disconnect the quick-lock at battery if the truck is parked/stored/stowed/transported more then 36
hours
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A
NOTE For Euro 4/5 trucks!
The UREA pump in the after-treatment system needs 90 seconds to empty the UREA hoses!
This is needed to avoid that the UREA is freezing and consequently damages the system!
Wait 90 seconds = UREA pump stops Æ then disconnect the battery cable!
DR Remote control El main switch manual main switch
1. Ignition OFF 2. Switch OFF the main switch (ADR inside the cab) lock the doors with remote or key.
(If equipped with main-switch)
3. Open cap lock switch 4. Put cable in between the batteries, put on the battery box cover
Incorrect position Correct position
5. Do NOT leave the cap lock open!!! 6. Cable is fixed between the batteries
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3.6 Central locking
Unlock with the sender
Unlock the driver’s door
Press the symbol for UNLOCK
The indicators will flash
Unlock the passenger door
1 Unlock the driver’s door using
UNLOCK
The indicators will flash
2 Press the symbol for UNLOCK again
The indicators will flash
Lock with the sender
Press the symbol for LOCK
The flashers light up
Unlock with the key
1 Unlock
A door is unlocked
2 Lock
3 Unlock again
Both doors are unlocked
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