Volvo Truck 2005 User Manual
Service Manual
Trucks
Group 00
Release 02
Dismantling manual for Volvo Trucks
20068517
Foreword
The descriptions and service procedures contained in this manual are based on designs
and methods studies carried out up to January 2005.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is judged to have a significant bearing on this manual, supplementary service
bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a
reference to V.S.T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for general
information and no reference is made to V.S.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to have
the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafepractice where serious personal injury or death could occur.
Volvo Truck Corporation
Göteborg, Sweden
Order number: 20068517
© 2005 Volvo Truck Corporation, Göteborg, Sweden
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 Truck Corporation.
ENG20676
Group 00 Dismantling manual for Volvo Trucks
Disassembly instructions
Contents
“Introduction” page 2
“Volvo and the environment” page 3
“The Volvo environmental policy” page 3
“Legislation, protection and safety regulations” page 3
“Recycling” page 4
“Labelling” page 4
“Hazardous waste” page 4
“Chemicals and fluids” page 5
“Plastics” page 5
“Metals” page 5
“Handling hazardous waste” page 5
“Equipment” page 7
“General recommendations and preparations” page 7
“Emptying of components” page 8
“Disassembly instructions” page 17
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Group 00 Dismantling manual for Volvo Trucks
Introduction
Volvo’s three core values are quality, safety and respect
for the environment.
Correct handling also reduces costs and makes best use
of the economic value of components and material.
This manual has been prepared as one element of this
respect for the environment, to provide general guidelines
and information for the dismantling of a Volvo truck.
The aim is to give comprehensive information on how
dismantling should take place, whilst leaving a certain
amount of flexibility to permit a workshop to devise its
own methods and procedures for the work of dismantling,
and also to ensure that harmful waste and other material
that could cause harm to people or the environment is
handled in an environmentally correct manner.
This information is of a general nature because this
manual is applicable to different types of truck, which
means that certain details may vary between different
truck models. However the important information still
applies.
For more detailed information and working instructions
refer to the other service information in the respective
groups from 1 to 9.
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Group 00 Dismantling manual for Volvo Trucks
Volvo and the environment
Respect for the environment is, along with safety and
quality, one of the three Volvo core values.
Taking care of the environment expresses the concern
of the Volvo Group to actively improve its environmental
work and to reduce the effect on the environment of
the products and processes involved in its business
operations.
The Volvo environmental policy
The environmental policy of the Volvo Group is built up
around the following strategies:
Overview
•
The company’s products are placed in a larger
context where efforts are concentrated on reducing
the effects on the environment of the products and
processes in the business at every stage of the life
cycle, from the original ideas to dismantling and waste
handling. Customers, society in general, distributors
and subcontractors are also included in this chain.
Continuous improvement
•
Environmental work shall be integrated and followed
up in all respects to maintain continual improvement.
This is expressed in the Volvo environmental policy, that
shall permetate through, not only vehicle manufacture,
but the whole life cycle of each vehicle, including the
dismantling process and disposal of the remains.
Technical development
•
The requirement for care of the environment shall be
achieved through active research and development
within such areas as transport, legislation and
reduction of the effects on the environment of products,
also aiming to reduce the use of environmentally
harmful material.
Efficient use of resources
•
The whole life cycle shall be taken into account in
respect of products and processes in order to utilise
resources as efficiently as possible and to facilitate
waste handling.
Legislation, protection and safety regulations
All dismantling operations shall take place in accordance
with applicable national legislation and ordinances in the
areas of the environment, health and worker protection.
This includes all work, handling, sorting, transportation,
storage and other treatment of components, chemicals,
filters and other material.
Respect shall be shown for land, surface water and
sewage to avoid their pollution. Harmful substances and
dangerous waste shall be handled and treated in well
ventilated spaces in accordance with legislation and
regulations.
Local safety instructions shall be familiar to and respected
by the staff.
Environmentally harmful waste shall be transported by a
carrier that has been approved by the authorities.
Volvo’s own white, gray and bvlack chemical lists shall
be followed.
The work of dismantling involves contact with many
substances that can pose risks to both the environment
and health. It is therefore necessary to have the right
knowledge, equipment and preparations in order to
minimise these risks and to create the conditions for a
safe job.
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Group 00 Dismantling manual for Volvo Trucks
Recycling
Trucks are manufactured on the premise that as much as
possible of their material can be recycled, and more than
90% of today’s trucks consist of recyclable material.
The easiest material to recycle is metals, but in certain
cases the shape and installation of components can
hinder the recycling process.
During truck development the LCA method (Life Cycle
Analysis) is used to evaluate whether certain proposed
materials should be used or avoided. Some types of
material are completely forbidden within Volvo, whilst
others may be used in only limited quantities.
Labelling
During the work of dismantling plastics, metal, chemicals,
fluids and other material should be sorted and taken care
of in a suitable way in accordance with local legislation
and regulations. Material that is labelled shall be handled
in the prescribed manner. To facilitate the identification
and sorting of various materials Volvo has issued a
number of standards for labelling of material.
Material can be recycled in different ways:
Component recycling
•
Removed components used as second-hand spare
parts, such as engines and gearboxes.
Material recycling
•
Material recycling means that the material is reclaimed
and used again, such as glass recycling.
Energy recovery
•
Energy reclamation means that the stored energy
in waste is utilised. Various kinds of energy can be
extracted by burning detail parts and components.
Disposal by dumping
•
If waste cannot be recycled or reclaimed, disposal by
dumping may be an alternative, i.e. detail parts that
cannot be recycled in any way may be dumped.
Plastics
STD 103-0002 “Material identification and labelling of
plastic articles” is an application of European legislation
concerning the definition of coding standards for
components and material in vehicles in accordance
with the European Parliament and Council Directive
2000/53/EC on end-of life vehicles.
Rubber
Rubber is labelled in accordance with STD 5052,21
“Colour marking of rubber articles”. This standard also
contains regulations for labelling rubber hoses with text.
Hazardous waste
A truck contains a number of different materials and
chemicals that can have a negative effect on the
surrounding environment and on human health, if not
handled properly.
All dismantled products must be dealt with in accordance
with local legislation and regulations.
Metals
Metals are labelled in accordance with STD 5052,11
“Labelling of metallic objects”.
Particular respect shall be shown in the case of contact
with such material, fluids and chemicals.
Refer to the Volvo “Dealer Operating Standard” for more
detailed information.
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Group 00 Dismantling manual for Volvo Trucks
Chemicals and fluids
Fluids and other chemicals that can be found in Volvo
trucks include engine and transmission oils, brake fluid,
lubricating grease, fuel, clutch fluid, coolant, washer fluid,
glycol, sulphuric acid, urea solution and refrigerant.
All chemicals and fluids shall be drained or removed from
the vehicle that is to be scrapped.
Plastics
Plastics can be divided into two groups: thermosetting
plastics and thermoplastic resins.
The fluids from a truck can be reclaimed for either their
material or energy content.
For information concerning oil and fluid volumes refer
to the service information “Lubrication service and oil
changing”, Group 175.
Thermoplastic resins can be recycled by melting them
down.
Thermosetting plastics are in general difficult to recycle
and can only be recycled as filling material or as fuel.
These plastics have a low energy value.
Metals
The use of certain metals leads to their accumulation in
the biosphere, namely many poisonous metals such as
lead and mercury that can be present in batteries, lamps
and electronic equipment. Most of the weight of a truck,
about 90%, consists of the metals iron and steel, but also
present are aluminium, brass, copper, nickel, tin, bronze
and molybdenum in smaller amounts.
Handling hazardous waste
Chemicals and fluids
Oil
•
After draining can be cleaned and re-used, or burned
for energy reclamation.
Make sure that no oil is poured out into drains! This
can cause problems for waste water purifying plants.
Contact the local authority for information.
Ensure that oil is not polluted by other fluids such
as water, coolant or solvents, as polluted oil is much
more difficult and expensive to recycle.
Solvents
•
Solvents can be cleaned and re-used.
Plastics shall only be burned in approved incineration
stations!
Metals are the materials that are normally the easiest to
recycle. Most metals can be recycled but not have their
energy reclaimed.
Iron and steel should be separated from other metals,
such as aluminium, copper and brass.
Coolant
•
Coolant can be recycled.
The fluid is toxic and can contain heavy metals, so
it should never be poured on to the ground, into
drains or watercourses.
Brake fluid
•
Brake fluid can be recycled, or burned for energy
reclamation.
Never pour brake fluid into drains!
Brake fluid should not be polluted if it is to be
recycled, this makes the process much more
expensive.
Nover pour solvents into drains, this is deemed
hazardous waste in most countries.
Neverpour solvents on to the ground as this pollutes
the both the land and its ground water.
Urea solution
•
Urea solution cannot be reused.
Urea solution must not be poured in to drains, it
must be collected in a separate container.
Do not allow urea solution to come into contact
with other chemicals. Spills must be wiped up with
absorbing agent.
Refrigerant
•
Refrigerant can be recycled, but if this is not possible, it
should be taken in hand by a certified refrigerant disposal
company.
Glycol
•
Can be recycled after purification by distillation.
Glue
•
Cannot be recycled. In addition its presence can
reduce the chances of recycling other material.
Washer fluid
•
Can be filtered and re-used.
Sulphuric acid
•
Can be purified and re-used.
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Group 00 Dismantling manual for Volvo Trucks
Other material
Batteries
•
Truck batteries shall be taken care of by an authorised
waste disposal company. Smaller or other types of
battery contain valuable metals that can be reclaimed
and re-used.
Fluorescent lamps and tubes, components
•
containing mercury and switches.
These components shall be taken care of by an
authorised waste disposal company.
In most countries it is illegal to dump batteries, as
this can cause serious harm to humans and animals.
Lead is highly toxic and accumulates in the body
over time.
Sulphuric acid is extremely corrosive.
Air bags and belt tensioners
•
Air bags and belt tensioners must be dealt with in
accordance with local legislation and regulations.
CAUTION
Air bags and belt tensioners contain explosive
substances and must always be handled with extreme
care. Refer also to Volvo Policy and “Safe Working
Practices för SRS-airbag”.
Oil filters and other filters
•
Filters can be efficiently re-used after draining,
reclaiming the energy from paper and rubber parts,
and recycling clean metal.
Filters contain oil and other harmful substances.
Check local legislation and regulations for handling
these.
Never dump this type of component as rubbish, as
they are dangerous to humans and animals. In most
countries this is illegal.
Gas discharge lamps
•
Gas discharge lamps contain mercury and are
hazardous waste. They must not be dumped as
rubbish. These components shall be taken care
of by an authorised waste disposal company.
Brake discs and drums
•
These parts can be re-used and the metal parts can
be recycled.
In earlier truck models these components may
contain asbestos. Take precautions to minimise
the amount of asbestos dust being spread while
working.
Rubber
•
Can be difficult to reclaim and also may contain
chlorine or fluorine. Mainly in truck tyres, that can be
ground down and re-used as raw material for new
tyres, or burned to reclaim the energy.
Rubber may only be burned in approvedincineration
plants, as the smoke can cause serious air pollution.
Laminated glass
•
The glass can be recycled.
Electrical and electronic waste
•
These components contain valuable and recycleable
components, along with a number of chemicals (PCB,
heavy metals, etc.) with characteristics that are
environmentally harmful. Other parts can be burned to
reclaim energy.
Never dump hazardous electrical and electronic
waste.
Wood products
•
Can be recycled, or burned for energy reclamation.
Paper
•
Paper, cardboard and paperboard should be sorted
and recycled, but burning to reclaim energy is also an
alternative.
Paint
•
Waste paint may be hazardous as many paints contain
hazardous metals such as lead, cadmium, barium and
chrome.
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Group 00 Dismantling manual for Volvo Trucks
Equipment
Local
Tools
The work of dismantling should be carried out in well
ventilated premises that are equipped in accordance with
health and safety protection and other legislation and
regulations.
Equipment for fire extinguishing, first aid and eye washing
should be accessible in the premises!
Protective equipment
At various times during dismantling personal protective
equipment is to be used when necessary. This includes
protective clothing and footwear,safety goggles, gloves,
ear defenders, helmets and face masks.
It is important that the work of dismantling is carried out
using suitable tools from both the environmental and
worker safety aspects. Volvo therefore recommends that
dismantling workshops invest in this type of equipment.
Among the tools that could be highly suitable for
dismantling are: equipment for draining refrigerant,cutting
torches, welding or similar equipment, lifting gear, stands,
crowbars, adjustable wrenches, hammers and nut drivers.
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General recommendations and preparations
It can be good to bear the following recommendations
in mind when dismantling:
Assess first which parts of the ruck can be recycled
•
or reclaimed, and use this as a starting point when
determining the dismantling procedure.
Before dismantling begins the pressure in the SCR
•
system must be released and the urea solution
emptied out. This process begins automatically when
the engine is switched off. Wait 2 minutes after
switching off the engine before commencing any work
on the vehicle.
Note: If the electrical power is switched off or interrupted
in any other way before the emptying procedure is
completed, for example with the ADR, main circuit breaker
or by removing a battery pole cable, the SCR system will
not be emptied and may continue to retain pressure!
Urea is highly corrosive to metal and can damage
•
electrical connectors. If urea solution comes into
contact with disconnected electrical connectors, the
urea solution spreads rapidly through the wiring and
oxidises the metal.
Before commencing dismantling, switch off the electric
•
current and disconnect the batteries. Then begin by
removing the SRS system.
Release the pressure in a controlled way!
•
Drive the air suspension as low as possible before
commencing dismantling!
Note that it is very important to separate and sort
•
the various fluids, plastics and metals throughout the
entire process.
If the vehicle is very dirty it should first be washed.
•
Lift off any additional superstructure before
•
commencing dismantling of the truck.
Empty loose parts out of the cab before starting to
•
dismantle.
Put removed items out of the way while the work is
•
going on, so that they do not get in the way and pose a
risk to the work.
As cables and material is released or dismantled,
these should be cleared away and sorted.
When removing pressure hoses, note that there is a
•
risk that they may still be pressurised. Do not release
the whole hose at once, first loosen it carefully and let
any oil or air it may contain leak out first. Then release
the whole hose.
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Group 00 Dismantling manual for Volvo Trucks
Emptying of components
Components should be emptied as much as possible
before dismantling commences.
Some drain locations may become easier to access later
during the work.
See below for the components that are involved, although
these are not in any particular order.
For more detailed information and working instructions
refer to the other service information in the respective
groups from 1 to 9.
Fluids and chemicals shall be handled, separated and
stored in a suitable way and in accordance with local
legislation and regulations.
Engine, oil and filters
Drain the engine oil through the drain plug (A).
Remove the engine filters; the full flow filter (B) and
bypass filter (C).
WARNING
Be careful! Use protective goggles, gloves and face
masks where necessary.
Manual gearbox, oil and filter
Drain and empty the gearbox oil through the drain plug
(C).
Unscrew the oil filter housing and remove the seal and
oil filter.
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