Volvo VN, VHD Service Manual
Service Manual
Trucks
Group 177–500
Preventive Maintenance
Basic Service
VN,VHD
PV776-TSP151476
Foreword
The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to December 2001.
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 believed 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 refer-
ence to an S.R.T. (Standard Repair Time).
Service procedures which do not include an operation number in the title are for gen-
eral information and no reference is made to an S.R.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 unsafe practice where serious personal injury or death could oc-
cur.
Volvo Trucks North America, Inc.
Greensboro, NC USA
Order number: PV776-TSP151476
© 2001 Volvo Trucks North America, Inc., 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, Inc..
Contents
General .................................................................................................... 3
Preventive Maintenance, General ........................................................... 3
Safety Advice ......................................................................................... 7
Specifications ......................................................................................... 9
Engine .................................................................................................... 9
Transmission ........................................................................................ 12
Rear Axle ............................................................................................. 13
Tools ...................................................................................................... 14
Special Tools and Special Equipment ................................................. 14
Preventive Maintenance Inspection Bay ............................................. 21
Design and Function ........................................................................... 23
Clutch ................................................................................................... 23
Power Take-off ..................................................................................... 25
Driveshaft ............................................................................................. 25
Brakes .................................................................................................. 26
Steering System .................................................................................. 27
Hubs .................................................................................................... 28
Chassis ................................................................................................ 29
Cab ...................................................................................................... 30
Preventive Maintenance ...................................................................... 31
Basic Service ....................................................................................... 31
............................................................................................................... 97
Additional Time Based Maintenance ..................................................... 97
............................................................................................................... 99
Additional Mileage Based Maintenance ................................................ 99
Feedback
1
2
Group 177 General
General
Preventive Maintenance, General
Introduction
This manual describes inspection and lubrication requirements during the Basic Service of Volvo VN/VHD
vehicles. The purpose for doing the preventive maintenance is to ensure that the vehicle is safe and
roadworthy over its full lifetime.
The driver is taking part in the continuous preventive
maintenance program by completing the required Daily
Pre-trip Inspection. This is a purely visual inspection that
is designed to detect any obvious problems that would
make the vehicle unsafe to take on the road. Added to
the Pre-trip Inspection is the Preventive Maintenance
Program that is typically carried out by trained personnel
using a systematic approach to cover all important components of the new vehicle.
Preventive Maintenance is a planned vehicle maintenance program that provides an orderly series of
servicing and inspecting procedures. A well applied
maintenance program realizes the investment made in
the vehicle. The difference between a poorly maintained
vehicle and a well maintained vehicle will not show up
until later mileage. Good maintenance is necessary to
assure the designed life expectancy of the vehicle and
its individual components.
Maintenance Coverage
There is no firm maintenance program that will apply to
all operations. A basic maintenance program is not difficult to set up; to make the program the most effective
takes time and effort, and is based around the needs
and experiences of each individual operation. The program in this service manual covers all types of Volvo
VN/VHD vehicles with medium to high mileage and
sometimes high loads.
Use this established maintenance program as a base to
tailor an individual maintenance program for customers
that have requirements that are outside of the scope of
this program.
To establish an individual program, look at information
sources that are usually available, such as:
Driver’s repair or complaint reports.
Unusual parts usage.
Repetitive failures or problems found in inspection.
Unscheduled maintenance or repairs.
Road failures.
3
Group 177 General
Program Structure
This maintenance program has been based on the
progress in vehicle technology and increases in oil quality to simplify the maintenance.
For simplified scheduling, the program has tied maintenance to logical time or mileage limits that make it easy
to anticipate needed servicing. For the majority of onhighway operators, the 24,000 km (15,000 miles) or 4
months schedule can be used with little change.
It is important that the scheduled intervals are followed
as limits. Maintenance can be done before either 24,000
km (15,000 miles) have been reached or before 4
months are up but must be made at or before either the
mileage or the time limit has been reached.
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components, All Models”,
Publication Number 175–001, and any appropriate vendor literature.
Advantages
A well-planned preventive maintenance program offers
the following advantages:
There are many time — and/or mileage-based — service items that are not listed on the form. Look at the
end of this document for a listing of additional components that may need to be serviced, depending on the
mileage or time since last service.
Maintenance Records
It is important to use the inspection form together with
other reports to come up with the best maintenance program for a specific application. Use driver’s reports,
complaints, parts usage, repetitive failures, previous repair orders, road failures, etc. to build a maintenance
history.
Records should be collected over the lifetime of the vehicle to form a permanent vehicle record file. The vehicle
file should be used to customize the operational maintenance needs.
The “Driver Inspection Form” is also required by
Federal law. The use of this inspection report makes
the driver a part of the maintenance program and
places direct responsibility on the driver to report
problems that may come up during operation. When
properly used, there should be no excuse for a defective vehicle being in service.
The lowest attainable maintenance cost.
Maximum vehicle uptime.
Better fuel economy.
Reduced road failures; greater dependability.
Increased customer confidence, better public rela-
tions.
Less possibility of accidents due to defective equip-
ment.
Fewer driver complaints.
Regardless of the planning and the details of the maintenance program, the success of the program hinges on
the caliber of workmanship in performing the actual
inspection. A major cause of failure is a “pencil inspection;” that is, the mechanic checks off each operation as
being OK without making the actual inspection. A “pencil
inspection” defeats the purpose of the inspection, which
is to detect an impending failure.
Maintenance Form
A Service Manual is issued detailing the current inspection forms. Forms are created for different users but all
with the same references to this document. When the inspection point is carried out, check the box if the item is
OK. If further work, such as adjustment, repair, etc.,
needs to be performed, record this information and go
on with the next inspection point. Items noted as being
faulty or in need of adjustment need to be shown to the
customer and scheduled for repair.
4
Basic Inspection
Note: The included Basic Service checklist is an
original copy. The document can be updated without
notice.
The Basic inspection is carried out at a maximum of
24,000 km (15,000 miles) or 4 months, whichever comes
first.
All inspection points are to be carried out as verification
of function or condition. Any defects are noted on the inspection form for later correction, if so ordered by the
vehicle owner.
Note: The standard repair time for performing the
Basic Service Preventive Maintenance is based on
inspection and Oil and Filter Change, without repair
or adjustment.
Annual Inspection
The Annual inspection is carried out yearly in addition to
a Basic inspection. This inspection is designed to open
up components for inspection or using test equipment to
record performance.
The ideal time to carry out the Annual inspection is right
before the hardest season, which means just before winter in the cold weather climates and just before summer
in the hot weather climates.
For further information refer to “Annual Preventive Service Manual”, Publication Number 177–501.
Group 177 General
Other Inspection
There are additional service points that are carried out at
specific mileage or time intervals. These are not part of
the Preventive Maintenance Basic time. They should be
scheduled as an adjustment or repair job carried out at
the same time as the Preventive Maintenance, and are
listed in this document as reminders only.
5
Group 177 General
Noise Emissions
Volvo Trucks North America, Inc. 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,
Inc. was designed, built and equipped to conform, to all
applicable U.S. EPA Noise Control Regulations, at the
time it left the control of Volvo Trucks North America, Inc.
This warranty covers this vehicle as designed, built and
equipped by Volvo Trucks North America, Inc., and is not
limited to any particular part, component or system of
the vehicle manufactured by Volvo Trucks North America, Inc. Defects in design, assembly or in any part,
component or system of the vehicle as manufactured by
Volvo Trucks North America, Inc., which, at the time it
left the control of Volvo Trucks North America, Inc.
caused noise emissions to exceed Federal standards,
are covered by this warranty for the life of the vehicle.
Tampering with Noise Control System
Noise Shields and Insulation
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 truck body
mounted sound insulation components and/or shields
(e.g., cab or fender shields, skirts, wheel housing splash
shields, etc.).
Engine Control and Fuel Systems
Removing or rendering inoperative, or modifying the engine control system (such a the ECU or the fuel system
components) in order to allow the engine to operate outside of the manufacturer’s specifications (e.g., exceeding
the manufacturer’s engine speed limits).
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 those acts presumed to constitute tampering are
the acts listed below:
Cooling System
Removing or rendering inoperative cooling system components (e.g., temperature-controlled fan clutch, fan
shroud, fan ring, recirculation shields, etc.).
Exhaust System
Removing or rendering inoperative exhaust system components (e.g., muffler, pipes, clamps, etc.).
Air Intake System
Removing or rendering inoperative air intake/induction
system components (e.g., filter, filter housing, ducts,
etc.).
6
Group 177 General
Safety Advice
Never operate a diesel 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 make the engine overspeed, causing severe damage and/or explosion or
fire. Serious personal injury or death can occur.
When entering and exiting the cab, use caution. Always have a firm hand hold and/or stable foot position
before transferring weight to that position. Do not
carry anything when entering or exiting. Make sure
the soles of your shoes and the cab steps are free
from dirt, grease, oil or moisture before using the
steps. Failure to do so can result in a fall, and serious
personal injury or death may occur.
Always chock the wheels before working under the
vehicle to prevent it from rolling. Failure to do so can
result in unexpected vehicle movement and serious
personal injury or death could occur.
If using a jack and/or jack stands, choose proper
fault-free equipment. Failure to do so can result in
equipment failures and personal injury or death may
occur.
Note: During the Preventive Maintenance inspection,
check the condition of warning labels on the vehicle. If a
label is damaged or defaced to the point where the message cannot be read, note on the inspection form to
have it replaced.
7
8
Group 177 Specifications
Specifications
Engine
General
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” Publication
Number 175–001, and any appropriate vendor literature.
of the combustion by-products that contaminate the oil.
These contaminates will make the change intervals the
same as for regular oil. However, in extreme driving conditions, a synthetic oil may be the only choice for the
application.
In a modern diesel engine it is very important to have
regular oil changes. The demands of pulling high loads,
pulling at high elevations, extreme high or low temperatures and longer service intervals, make the choice of
correct oil a hard task. The Volvo dealer, the engine
manufacturer or the oil manufacturer has the expertise to
analyze driving conditions and to recommend what oil
gives the best protection and economy.
Oil
The engine oil has the task of lubricating, sealing, cooling and cleaning the engine. Filtering the intake air and
using a low sulfur fuel helps the oil protect the engine
parts. With better engine designs and improved oils, the
service intervals have steadily increased. The interval
choice depends on the engine manufacturer specifications. Make sure the correct oil type and also the correct
viscosity are chosen for the mileage interval driven.
Periodic oil testing is recommended. The test results
give a continuous picture of the health of the engine and
can warn well in advance of a problem developing.
The intervals will not cover all applications. In on/off
highway driving, severe off highway, continuous stopand-go city driving and extremely high mileage, the oil
change interval and preventive maintenance schedule
need to be customized for the best protection and economy. The intervals listed in these specifications are
guidelines that should be used in establishing a correct
maintenance program.
CAUTION
Note: It is not recommended to mix synthetic oils with
petroleum-based oils.
Coolant
The engine coolant protects the cooling system from
freezing or boil over problems. It also protects against
corrosion and cylinder liner pitting. Coolant requirements
are based on the additive levels present in the cooling
system. To be able to run the cooling system as long as
2 years between coolant changes, there must be a replenishment of additives as they are used up. Testing
should be done regularly to be sure the additive levels
are within recommended levels.
Never run the engine with only water in the cooling
system. Always use a mixture of clean water and a recommended antifreeze. The mixture should never be less
than 40% antifreeze and 60% clean water or more than
60% antifreeze and 40% clean water.
Note: For further information on Long life coolant refer to
Service Bulletin 260–002, “Texaco Extended Life
Coolant.”
CAUTION
Long life coolant is colored red for identification purposes, so as not to mistake it for conventional, green
coolant. Long life coolant will test as out of additives
(SCA), but SCA should not be added.
Adding unknown additives may put the engine at risk
of failure. There are many aftermarket oil additives
that claim improved performance if added to the engine oil. Each oil type recommended already contains
additives that have been tested by a collaboration with
engine and oil manufacturers.
Synthetic oil is offered as an alternative to the traditional
petroleum based oil for the engines. The ability of synthetic oil to protect the engine is better than regular oil
but its life is the same as for regular oil. This is because
Fuel
The sulfur content in low-sulfur fuel has been regulated
to a maximum of 0.05% per weight for No.2–D diesel
fuel. For fuels that have a sulfur content of 0.5% by
weight and above, most engine manufacturers are requiring that oil is changed at shorter intervals. Sulfur
creates highly acidic pollutants in the oil that break down
the additives at a higher rate. If fuel with a higher sulfur
content is used, the engine manufacturers recommend
that the oil change intervals be reduced.
9
Group 177 Specifications
VOLVO ENGINES
Note: It is not recommended to mix synthetic oils with
petroleum based oils.
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
Maximum change intervals are 40,000 km (25,000 miles)
if using oil that meets the Volvo Drain Specification
(VDS). If the oil does not meet the requirements according to VDS, change intervals should be 24,000 km
(15,000 miles). Contact Volvo or a Volvo authorized
dealer to obtain a list of approved VDS oils.
Shorter oil change intervals maybe required if the engine
is operating in a dusty environment or if frequent stops
and starts are made (see oil change interval below).
Supplemental coolant additives are recommended for all
Volvo cooling systems. Antifreeze alone does not provide
sufficient corrosion protection for heavy duty diesel engines.
If the fuel has a sulfur content exceeding 0.5% by
weight, halve the indicated maximum mileage intervals.
Oil filters should always be changed when changing oil.
CUMMINS ENGINES
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
If engine is operating in ambient temperatures consistently below - 20
perform maintenance at shorter intervals. Shorter intervals are also required if the engine is operating in a dusty
environment or if frequent stops and starts are made.
Oil filters should always be changed when changing oil.
Supplemental coolant additives are recommended for all
Cummins cooling systems. Antifreeze alone does not
provide sufficient corrosion protection for heavy duty
diesel engines.
C(0F) or above 40C (100F),
10
Group 177 Specifications
DETROIT DIESEL ENGINES
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
The use of fuels with a sulfur content above 0.5% by
weight will require more frequent oil changes. Refer to
Detroit Diesel Publications for details. More frequent oil
changes are also required if the engine is operating in a
dusty environment or if frequent stops and starts are
made (see oil change interval below).
Oil filters should always be changed when changing oil.
Supplemental coolant additives are recommended for all
Detroit Diesel cooling systems. Antifreeze alone does
not provide sufficient corrosion protection for heavy duty
diesel engines.
Note: The Detroit Diesel Engine is installed in earlier VN
vehicles (from 1996–2000) only.
CATERPILLAR ENGINES
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
Caterpillar does NOT recommend an automatic extension of oil drain intervals with high quality oil, low sulfur
fuel and non-severe duty driving. Oil drain intervals can
only be extended with an oil analysis program containing
the following elements: oil condition and wear metals,
trend analysis, fuel consumption and oil consumption.
In areas where fuel sulfur content exceeds 1.5%, choose
an oil with a total base number that is within the API
CF-4 or CG-4 categories and shorten the oil change period based on oil analysis.
Shorter oil change intervals are required if the engine is
operating in a dusty environment or if frequent stops and
starts are made (see oil change interval below).
Oil filters should always be changed when changing oil.
Supplemental coolant additives are recommended for all
Caterpillar cooling systems. Antifreeze alone does not
provide sufficient corrosion protection for heavy duty
diesel engines.
Note: Caterpillar Engines were installed in later model
VN vehicles (from 1996–1999) only.
11
Group 177 Specifications
Transmission
Includes Volvo, Eaton Fuller, Meritor, and Allison HD Transmissions
For further information concerning component specifications see service information in
Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number
175–001, and appropriate vendor literature.
12
Group 177 Specifications
Rear Axle
Includes Volvo, Arvin Meritor, and Eaton Dana Rear Axles
For further information concerning component specifications see service information in
Group 1, “Oil and Filter Change Intervals for Volvo Components,” publication number
175–001, and appropriate vendor literature.
13
Group 177 Tools
Tools
Special Tools and Special Equipment
The following special tools are recommended for use in the preventive maintenance inspection. Special tools can be ordered through Volvo Special Tools program in the parts
ordering system or already from Kent-Moore by calling (800) 328–6657. (Kent-Moore
tools are preceded by a J.) Please refer to the specific tool number when ordering.
Special Tools
J-42942
ABS Sensor Adjustment Tool
(Kent-Moore)
J-44399
Air System Tester
J-42189
Airline Release Tool
(Kent-Moore)
J-44773
Airline Release Tool
J-44769
Wheel Speed Sensor Extractor
14
J-44966
Wheel Speed Sensor Remover for Heavy Duty Steer Axle
and Aluminum Hub
Group 177 Tools
Special Tools (Continued)
J-44302
A/C Schrader Valve Core Removal Tool
J-22610
Drive Shaft Boot Camp Pliers
J-443338
Oil Dipstick for A/C Compressor
J-43143
Tie Strap Tensioner
J-41610
Feeler Gauge Set
J-44392
Fan Belt Tensioner Tool
15
Group 177 Tools
Special Tools (Continued)
PT 5900
Chip Vacuum
J-38641-B
Diesel Fuel Hydrometer
9998142
Charge Air Cooler Pressure Tester
J-44544
Ride Height Gauge
16
000700
Rim Flange Wear Gauge
Group 177 Tools
Other Special Equipment
J-42397-A
Coolant Pressure Test Adapter
J-38460-ADigital Inclinometer J-36795
1089953
Bulb Removal Tool
Tandem Axle Calipers
J-23600-B
Belt Tension Gauge
3093472
Timken Wheel End Play Gauge
9996791
Spring Pin Socket
17
Group 177 Tools
Other Special Equipment (Continued)
9998691
Oil Filter Nipple Installer Kit
3947553, 3949521, 3946522, 3949523
Terminal and Shim Kits
18
J-44701
Battery Tester Kit
J-44778, J-44779
Driveshaft U-Joint and Yoke Kits
Group 177 Tools
VCADS Pro Tools
The following hardware is used to operate VCADS Pro. The tools can be ordered from
Volvo Trucks North America; please refer to the specific tool number when ordering.
7
1 PC tool-package
2 9998555, Communication interface unit
3 9812331, Extension cable
4 J-43999, 6 pin Diagnostic adapter (for VN vehicles
prior to 1999)
5 J-43939, 9 pin Diagnostic adapter (for VN vehicles
built from January 1999)
6 9998496, Pressure gauge
7 9998495, Air Pressure Hose
19
Group 177 Tools
Lighting System, Special Tools
The tools listed below are used to complete maintenance on the Lighting System for
Volvo Trucks. They may be obtained from Volvo or, where indicated, from Kent Moore
at (800) 328-6657.
J-25300-D
Headlight Aiming Kit (Kent Moore)
J-42395
Rheostat Removal Tool (Kent Moore)
1089953
Lamp Removal Tool (Volvo)
20378326
Fuse Puller Tool (Volvo)
20
J-43244
Relay Puller Tool (Kent Moore)
Group 177 Tools
Preventive Maintenance Inspection Bay
Location
Preventive Maintenance is logically carried out at the
same time as lubrication of the vehicle. It is then natural
to use a bay with a grease pit to be assigned and
equipped for Preventive Maintenance. If a pit is not available, a regular workshop bay can be used, with jacks
added to the necessary equipment.
The bay needs to be well lit so inspection can be done
without having to use a flashlight (unless inspecting in
the frame).
Equipment
Inspection bay equipment should be specifically assigned to that bay and not be shared with the rest of the
shop. The floor equipment should have floor space for
storage in between using them and tools should be hung
on boards or stored in a cabinet for easy overview and
access.
Install mirrors in four corners of the bay so one person
can do a lighting function check without having to leave
the cab or rely on a spotter. Mirrors do not need to be
larger than truck door mirrors. Any type of equipment
that allows inspection by one person instead of having to
use a helper, makes inspection easier and faster.
21
22
Group 177 Design and Function
Design and Function
Clutch
General
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
Hydraulic fluid in the clutch system collects moisture
from the air and will eventually hold enough moisture to
affect the metal surfaces in the system unless removed.
Replace the fluid at the recommended intervals or more
frequently.
The clutch pedal play (1) is given by the clearance between the plunger and the piston (1a) in the master
cylinder. Thus the pedal will always have a play, regardless of the clutch adjustment. The correct play is adjusted
with the upper adjusting screw (1b) in the pedal carrier.
Volvo Clutch Slave Cylinder
Slave cylinder stroke (A) is 29 ± 1 mm (1.14 ± 0.04 in.).
The clutch pedal throw (2 - Figure 1) gives the stroke.
The lower adjusting screw (2a) limits the pedal throw
and thereby the clutch slave cylinder stroke.
Distance B should never be exceeded. The distance is
adjusted by removing the fork from the lever and reposition lever on the cross shaft.
Distance C is set when the clutch is new. During wear of
clutch, the distance will decrease. Readjustment should
not be needed before it is time to reface the clutch disc.
Fig. 1: Clutch
Fig. 2: Volvo Clutch Slave Cylinder
23
Group 177 Design and Function
Other Clutch Slave Cylinder
A slave cylinder for any non-Volvo clutch has a wear indicator. When the indicator is out of the operating range,
it is time to adjust the clutch.
To get the slave cylinder throw into the accepted range,
adjust the clutch plate until the indicator is in the operating range again.
1 Slave Cylinder
2 Mounting Bolts
3 Clutch Clevis Pin
4 Clutch Master Cylinder and Reservoir (Found
on the Bulkhead in the Engine Coupling)
24
Group 177 Design and Function
Power Take-off
Volvo PTO
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
Volvo PTO’s mount directly to the transmission and do
not need separate oil fill and check. Make sure there is
extra oil filled in the transmission for the PTO volume.
CAUTION
Transmission oil heat exchanger should be installed
when using PTO continuously over 15 minutes at a
time or with a continuous power output over 55 kW
(75 hp). Without heat exchanger, the oil can overheat
and transmission damage may follow.
If the application has a remotely installed pump or blower
with a driveshaft connection, the driveshaft U-joints need
to be greased at every maintenance interval or more often, depending on usage. Use a lithium based grease
with EP additives and of the consistency of NLGI No. 2.
Driveshaft
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
Use a lithium-based grease with EP additives with a
consistency of NLGI No. 2. Do not use conventional
chassis grease.
The driveshaft U-joints must be lubricated correctly for
the bearings to receive grease. The most common case
of U-joint failure is incorrect greasing. Always make sure
that grease is coming out of all four seals. If one seal
fails to purge old grease, move the driveshaft from side
to side while applying gun pressure. This allows for
greater clearance on the thrust end of the bearing that is
not purging. New grease flushes abrasive contaminants
from each bearing and assures that the bearing is filled
properly.
Failure to correctly grease the driveshaft U-joints or
slip-joints can lead to component failure which can result in separation of the driveshaft from the vehicle. A
separated driveshaft can result in major component
damage and loss of vehicle control, and can cause
serious personal injury or death.
25
Group 177 Design and Function
Brakes
Brake Cams and Slack Adjusters
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
Lubricate the brake cam bushings using a lithium based
grease with EP additives and consistency NLGI No. 2.
Fill grease until old grease has been pushed out past
the seal and new grease can be seen flowing.
Lubricate the slack adjusters using a lithium based
grease with EP additives and consistency NLGI No. 2.
Fill grease until old grease has been pushed out past
the splined shaft area, and adjustment pawl and new
grease can be seen flowing.
Air Dryers
Air dryers have internal maintenance systems that clean
out the accumulated moisture frequently and can therefore work with long maintenance intervals. Eventually the
drying medium will be filled up and the cartridge will
need to be changed. Change cartridge when there is
more water being drained in the daily emptying of the
tank than usual. This is a progressive development and
the time interval will be different from application to application.
Dryer manufacturers recommend changing cartridge every 2 to 3 years but intervals need to be adjusted for
application. The only dryer with regular maintenance is
the Midland, where the coalescent filter needs changing
every year.
26
Group 177 Design and Function
Steering System
Steering Linkage and Knuckles
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
Lubricate the Steering shaft and drag link.
Lubricated the tie rod.
TRW steering gears have a seal at the sector shaft that
needs greasing with a hand gun every 4 months or
more often if the weather and road conditions are severe.
Sheppard steering gears have seals at input shaft and at
the sector shaft that need greasing with a hand gun every 4 months or more often if the weather and road
conditions are severe.
No axial movement is allowable when 100 lbs. of hand
pressure is applied. Use hand pressure only, do not
check using pliers, wrenches or any other tools.
For all VHD Axle Back models, the steering shaft Ujoints should be inspected to see that the plastic caps
are intact. Complete this inspection every 4 months. A
shorter inspection period interval may be required if the
vehicle is operated under severe driving conditions.
For VHD Axle Forward models, grease the steering shaft
U-joints every 4 months. A shorter maintenance interval
may be required if the vehicle is operated under severe
driving conditions.
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Group 177 Design and Function
Steering System
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
A darkened fluid indicates a steering system that is running hotter than normal and the fluid is overheated.
Troubleshoot the reason for overheating and change
fluid.
Hubs
Oil Lubricated Hubs
For further information concerning component specifications see service information in Group 1, “Oil and Filter
Change Intervals for Volvo Components,” publication
number 175–001, and appropriate vendor literature.
Hubs are generally oil lubricated and should be lubricated during maintenance. Change oil when the hub is
removed for repairs.
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