Volvo VNL, VNM Operator's Manual
Operator's Manual
VNL and VNM
Foreword
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.
NOTE! 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, Inc. (VTNA) 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 (800) 424–
9393 (or 366–0123 in the Washington, DC area) or by writing to:
NHTSA, U.S. Department of Transportation, Washington, DC 20590.
Volvo Trucks North America, Inc.
Greensboro, NC USA
Order number: PV776-TSP20 154796
© 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 Information ............................. 1
Information For the Owner ................... 1
General Safety Information .................. 3
Modifications to Vehicle ....................... 7
Exhaust and Noise Emissions ............... 8
Vehicle Data ........................................ 16
Vehicle Access ...................................... 20
Cab Doors and Door Lock ................. 20
Cab Entry and Exit ............................. 22
Luggage Compartment ........................ 29
Hood .................................................... 30
Pre-Trip Inspection and Daily Mainte-
nance ..................................................... 32
General ................................................ 32
Pre-Trip Inspection Quick List ........... 33
Daily Maintenance .............................. 45
Additional Safety Features ................. 50
Safety Belts ......................................... 50
SRS Airbag ......................................... 61
Safety Equipment ................................ 68
VORAD Collision Warning System ... 69
Instruments and Controls ................... 70
Dash Overview .................................... 70
Instrument Cluster Overview .............. 71
Telltale Overview ................................ 72
Graphic Display Telltale Overview .... 73
Left Instrument Section ...................... 74
Main Instrument Section ..................... 82
Optional Switch Cluster .................... 112
Miscellaneous Switches .................... 113
Graphic Display ................................. 114
Graphic Display Overview ............... 114
Graphic Display Controls ................. 115
Graphic Display Telltales .................. 117
Information and Stop Messages ....... 118
Information Telltale ........................... 119
Stop Telltale ...................................... 126
Acknowledge Information and Stop
Messages ........................................... 130
Main Menu: Set-Up Mode ............... 132
Main Menu: System Diagnostic ....... 137
Main Menu: Data Log Mode (Volvo
Engine Only) ..................................... 152
Main Menu: Password Input ............ 158
Main Menu: Gauge ........................... 159
Main Menu: Fuel Economy (option) 163
Main Menu: Time/Distance .............. 165
Main Menu: FAULTS? ..................... 170
Heating and Air Conditioning ......... 174
General .............................................. 174
Climate Unit Main Control Panel .... 175
Sleeper Climate Unit ......................... 183
Cab Ventilation .................................. 185
Cab Air Filters .................................. 187
Parking Heater (optional) .................. 188
A/C Diagnostic Module .................... 194
Right Instrument Section .................... 89
Changing Telltale Bulbs In Cluster .... 95
Steering Column Switches .................. 97
Left Switch Cluster ............................. 99
Driving Light Switches ..................... 104
Right Switch Cluster ......................... 106
Pneumatic Switch Cluster ................. 110
Seats ..................................................... 195
General .............................................. 195
National Standard Seat Adjustments 196
National Comfort Seat Adjustments . 197
Volvo Standard Seat Adjustments .... 198
Volvo Comfort Seat Adjustments ..... 199
National Stationary Seat ................... 202
Cab Interior and Sleeper .................. 203
Brakes ................................................ 272
Interior/Reading Lights ..................... 203
Storage Compartments ...................... 206
Sleeper Bunks ................................... 212
VN-660 and VN–770 Sleeper Table 217
Sleeper Compartment Sink ............... 220
Miscellaneous Sleeper Equipment .... 224
Communication and Entertainment 231
Antennas ............................................ 231
Stereo/Radio ...................................... 233
Communication Equipment .............. 234
Television .......................................... 235
Fuel Economy Driving ...................... 237
Fuel Economy ................................... 237
Engine Start and Operation ............. 244
Starting the Engine ........................... 244
Cold Weather Start and Operation ... 249
Engine Operation .............................. 256
Cruise Control ................................... 265
Electrical System ............................... 292
Electrical System ............................... 292
Power Steering ................................... 309
General .............................................. 309
Axles and Wheels ............................... 311
Axles .................................................. 311
Wheels ............................................... 313
Fifth Wheel Instructions ................... 316
Fifth Wheel General Information ..... 316
Fifth Wheel ....................................... 319
Fifth Wheel Slider (option) .............. 320
Unlocking the Fifth Wheel ............... 321
Trailer Coupling Procedures ............. 323
Trailer Uncoupling Procedures ......... 328
Operating the Volvo Slider ............... 333
Emergency Information .................... 335
Towing Procedure ............................. 335
Fuel Tank Cap(s) ............................... 267
Clutch and Transmission .................. 269
Clutch ................................................ 269
Folding Gear Lever (option) ............. 270
Brakes ................................................. 272
Service Information ........................... 341
Service Assistance and Manuals ...... 341
Index .................................................... 343
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:
NOTE! A note defines an operating procedure, practice, condition, etc., which is
essential to proper operation of the vehicle.
CAUTION
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
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 danger label directs the operator’s attention to unsafe practices which could
result in serious personal injury or death.
The caution label is in white type on a
black background with a black border.
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 the manufacturer for any assistance.
In addition to this Operator’s 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.
General Information 1
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.
Various truck warranty coverage plans, contingent on application and weight class, are
available. Please contact an authorized
Volvo Truck Dealer for complete details.
Replacement warranty certificates for Volvo
Trucks are available from Volvo dealers.
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. Information concerning non-Volvo engines and/or
drivetrains can be obtained by contacting
the respective manufacturer.
For trucks placed in service after August 1,
2000 and operating in the USA and
Canada, Volvo dealers can print copies of
the Standard Truck Warranty Certificate
and the Premium (Purchased) Truck Coverage Certificate. Copies are available in
either English or Canadian French at the
dealer communication system (DCS) website. Look in the Service/Warranty folder.
NOTE! Federal law requires manufacturers
to notify owners of its products in the event
of a non-compliance to 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, Inc.
Att: Vehicle Registration Dept.
P. O. Box 26115
Greensboro, NC 27402–6115
United States of America
2 General Information
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 Operator’s Manual covers Volvo VNseries vehicles manufactured by Volvo
Trucks North America, Inc. with any of the
following designations:
VNL42T VNM42T VNL42 VNM42
VNL64T VNM64T VNL64 VNM64
L=long hood, M=medium hood
T=tractor
Explanation: The first number after the
model designation represents the total number of wheels (hubs) per vehicle. The
second number represents the number of
wheels (hubs) that drive the vehicle. Each
model designation also carries a suffix,
which identifies the cab type.
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.
Volvo Trucks North America, Inc. reserves
the right to make changes at any time or to
change specifications or design without notice and without incurring obligation.
W0001619
VN cab types
General Safety Information
Operating the Vehicle
Every vehicle, including heavy duty vehicles, has blind spots. The size of blind
spots varies from driver to driver and from
situation to situation. As a skilled, professional driver,
avoid accidents in turns, lane changes or
other maneuvers. Volvo Trucks North
America, Inc. provides standard equipment
(such as cabs, windshields, window sizes
and mirrors), preferred by most owners and
drivers under most conditions and in most
applications.
you are in the best position to
General Information 3
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.
However, due to differences in the size of
drivers, their seating positions, the way that
they use and operate their vehicles, personal preferences and other factors, no
combination of mirrors and other visibility
enhancement devices will eliminate all
blind spots in every situation.
The safe operation of this vehicle is up to
you. Because of your special preferences,
needs and circumstances, you may want to
add extra mirrors and/or other visibility enhancement devices. If so, you should
contact an authorized Volvo Truck dealer to
obtain those parts which best fit your own
personal needs and preferences.
WARNING
All items within the cab must be secured
before the vehicle is set in motion. This
includes, but is not limited to, drinks,
clothes, books, televisions, etc. In the
event of a collision, loose items could
fly around inside the cab. This could
cause personal injury.
4 General Information
Operating In Bobtail Mode
Tractors are equipped with a bobtail air
brake proportioning valve which automatically redistributes the braking force between
front and rear axles when not hooked up to
a semitrailer (bobtail operation).
When operating in bobtail mode, the rear
brake chambers receive reduced or proportional brake air pressure. When the tractor
is towing a trailer, the rear brake chambers
will receive full (normal) brake pressure.
NOTE! When operating bobtail, be certain
that glad hands, trailer air hoses, electrical
cable and connectors are properly stowed
and secure. Do not allow them to rub or
chafe on other components.
WARNING
When operating bobtail, the brake
system on the vehicle reduces the possibility of rear wheel brake lockup, except
on full pedal application. When bobtailing, be certain that adequate pedal
pressure is applied. There is no need to
reduce pedal effort. Failure to do so may
result in increased stopping distances.
Do Not Overload
This vehicle has been designed and assembled for a maximum gross vehicle weight
rating (GVWR) and a maximum front and
rear axle weights rating (FAWR and
RAWR). The actual rating for this vehicle
can be found on the label attached to the
door frame on the driver’s side. If any of
these three ratings is exceeded and overloading occurs, instability, poor handling,
failure of parts and accelerated wear can
occur.
Under no circumstances should the published GVWR, FAWR, and/or RAWR be
exceeded. Failure to observe these precautions can lead to the loss of vehicle
control, resulting in a crash causing serious personal injury or death.
General Information 5
Do not exceed the load rating of the
tires or the vehicle weight ratings. Overloading may result in tire failure causing
loss of vehicle control, leading to an accident resulting in severe personal injury
or death.
Operating
Before driving this vehicle, locate the instruments and controls, and become
thoroughly familiar with their operation.
After starting and when driving, always
check to make sure that the instrument
readings are normal.
W0001210
6 General Information
Reporting Safety Defects
USA
The National Highway Traffic Safety Administration (NHTSA) and Volvo Trucks
North America, Inc. 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 (800) 424–9393 (or 366–0123
in the Washington, DC area) or by writing
to: NHTSA, U. S. Department of Transportation, Washington, DC 20590.
1 (800) 424-9393
Canada
Refer consumer complaints to Volvo Trucks
Canada, Inc. or to the Transport Canada Department of Public Complaints, Recalls
and Investigations.
Mexico
Volvo Trucks of Mexico, S.A. de C.V.
should be informed immediately if you believe the vehicle has a defect that could
cause a crash, injury or death. Contact
Volvo Trucks de Mexico by calling or by
writing to: Volvo Trucks de Mexico, S.A.
de C.V., Prol. Paseo de la Reforma 600,
1er. Piso — 121, Col. Santa Fe Peña
Blanca, C.P. 01210, México, D.F.
NOTE! For a listing of other contacts for
information or help, see page 341.
1 (905) 795-1555
01 (800) 90 94 900
Modifications to Vehicle
Chassis Frame
Frame side rails are heat treated. No welding is permitted because structural failure
may result. Do not drill through either top
or bottom flanges. A warning label is also
attached to the frame for information.
Drilling is permitted in the frame web in
accordance with a specified hole spacing
pattern. Consult a Volvo Truck dealer to
obtain approved hole spacing dimensions or
refer to the Frame Rail and Cross Member
Service Manual.
General Information 7
W7000519
Frame rail and cross member nuts and bolts
should be checked periodically and tightened to the specified torque if necessary.
Frame Alterations
Under no circumstances can the frame be
cut and an extension piece added to increase the wheelbase. The only alteration
allowed is wheel base shortening, where
the only change in the frame rail is a new
hole pattern drilled for the new location of
the rear suspension.
Welding In Vehicle
Do not weld anywhere in or on the vehicle
before disconnecting batteries, all electronic
control units (ECU) and instrument cluster.
See page 298 for more information. Do not
use oxy/acetylene welding to repair cab
panels. Refer to the service manuals for
specific information.
WARNING
Do not weld on any part of the frame or
drill holes in the top or bottom flanges.
Serious structural damage could occur.
8 General Information
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 noncertified 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.”
delivery of the vehicle to the ultimate purchaser, and, in addition, no manufacturer or
dealer may make 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.
Modifications, such as reprogramming of
the fuel system so the engine will exceed
the certified horsepower or torque, or removing the mufflers are examples of illegal
changes.
Changes should not be made to a certified
engine that would result in an engine that
does not match the configuration of an engine model that is currently certified to
meet Federal Standards.
Specifically, please note that no person may
make such changes prior to the sale and
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.
General Information 9
California Emission Control Warranty Statement
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Volvo Trucks North America , Inc. (VTNA) are
pleased to explain the emission control system warranty on your vehicle. In California,
new motor vehicles must be designed, built and equipped to meet the State’s stringent
anti-smog standards. Volvo Trucks North America, Inc. must warrant the emission control
system on your vehicle for the periods of time listed below provided there has been no
abuse, neglect or improper maintenance of your vehicle.
Your emission control system may include parts such as carburetor or fuel injection system
and engine computer. Also included may be hoses, belts, connectors and other emissionrelated assemblies.
Where a warrantable condition exists, Volvo Trucks North America, Inc. will repair your
vehicle at no cost to you including diagnosis, parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
This warranty is appliccable for a period of five years, 100,000 miles or 3,000 hours of
operation, whichever first occurs. If an emission-related part of your vehicle is defective,
the part will be repaired or replaced by Volvo Trucks North America, Inc.
This is your emission control system DEFECTS WARRANTY.
OWNER’S WARRANTY RESPONSIBILITIES
As the vehicle owner, you are responsible for the performance of the required maintenance
listed in your owner’s manual. Volvo Trucks North America, Inc. recommends that you retain all receipts covering maintenance on your truck but Volvo Trucks North America, Inc.
cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
You are responsible for presenting your vehicle to a Volvo Trucks North America, Inc.
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 vehicle owner, you should also be aware that Volvo Trucks North America, Inc.
may deny you warranty coverage if your vehicle or a part has failed due to abuse, neglect,
improper maintenance or unapproved modifications.
If you have any questions regarding your warranty rights and responsibilities, you should
contact Volvo Trucks North America, Inc., Warranty Administration, (336) 393-2000 or
the California Air Resources Board at 9480 Telstar Avenue, El Monte, CA 91731.
10 General Information
EMISSION CONTROL SYSTEM WARRANTY
Volvo Trucks North America, Inc. WARRANTS TO THE ORIGINAL OWNER, AND
EACH SUBSEQUENT OWNER, OF A NEW TRUCK POWERED BY A VOLVO
DIESEL ENGINE THAT THE EMISSION CONTROL SYSTEM OF YOUR TRUCK:
1 Is designed, built and equipped so as to conform at the time of sale to all regulations
of the U.S. Environmental Protection Agency and the California Air Resources Board
applicable at the time of the manufacture; and
2 Is free from defects in material and workmanship which will cause the emission con-
trol components not to function as designed for a period of use of 5 years or 100,000
miles or 3,000 hours of engine operation, whichever comes first.
The 5 years/100,000 miles/3,000 hour warranty period shall begin on the date the vehicle
is first delivered to the first retail purchaser or if the vehicle is placed in service as a
demonstrator company vehicle prior to the sale at retail, on the date the vehicle is the first
placed in service.
The emission control system of your new Volvo engine was designed, built and tested using genuine Volvo parts, and the engine is certified as being in conformity with Federal
and California emission control regulations. Accordingly, it is recommended that any replacement parts used for maintenance, replacement or repair without invalidating this
warranty; the cost of such services or or parts, however, will not be covered under the warranty except in an emergency situation. A part not being available or a repair not being
completed within 30 days also constitutes an emergency.
Use of replacement parts which are not of equivalent quality may impair the effectiveness
of emission control systems. If other than Volvo parts are used for maintenance, owner
should obtain assurances that suck parts are warranted by their manufacturer to be equivalent to genuine Volvo parts. However, the use of other than Volvo replacement parts does
not invalidate the warranty on other components, unless such parts cause damage to warranted parts.
Repairs and service covered by the warranty will be performed by an authorized Volvo
Trucks North America, Inc. dealer at his place of business with no charge for parts or labor (including diagnosis) using Volvo parts for the emission control system, that requires
replacement and is covered by the warranty and found defective. In case of an emergency,
where an authorized Volvo Trucks North America, Inc. dealer is not available, repairs may
be performed at any available service establishment or by the owner, using any equivalent
replacement parts and Volvo Trucks North America, Inc. will reimburse the owner for such
repairs (including diagnosis) not to exceed Volvo Trucks North America, Inc’s suggested
retail retail price for the warranted parts and the labor rate appropriate for the geographical
area and the tasks performed.
Replaced parts and paid invoices must be presented to a Volvo Trucks North America, Inc.
dealer for reimbursement.
General Information 11
The emissions control parts covered by this Emission Control System Warranty are listed
under "What Is Covered by the Emissions Warranty." You are responsible for the performance of all required maintenance on your new Volvo engine, including maintenance or
repairs needed due to severe operating conditions. Volvo Trucks North America, Inc. will
not deny a warranty claim solely because you have no record of maintenance. However,
Volvo Trucks North America, Inc. may deny a warranty claim if your failure to perform
required maintenance resulted in the failure of a warranted part. Receipts covering the
performance of regular maintenance should be retained in the event questions arise concerning maintenance. The receipts should be transferred to each subsequent owner of the
vehicle with the emission warranted engine.
CUSTOMER ASSISTANCE
Volvo Trucks North America, Inc. wishes to help to assure that the Emission Control System Warranty is properly administered. In the event that you do not receive the warranty
service to which you believe you are entitled under the Emission Control System Warranty,
you should contact Volvo Trucks North America, Inc. Warranty Administration, (336) 393-
2000. The address and telephone number of each Regional Office is in your vehicle
owner’s manual. If you need additional assistance or information concerning the Emission
Control System Warranty, contact: Volvo Trucks North America, Inc., Warranty Administration, (336) 393-2000.
WHAT IS NOT COVERED BY THE EMISSION WARRANTY
This warranty does not cover:
1 Malfunctions in any part caused by any of the following: misuse, abuse, improper
adjustments unless performed by a Volvo Trucks North America, Inc. dealer, modifications, alterations, tampering, disconnection, improper or inadequate maintenance, or
use of fuels not recommended for the engine as described in the owner’s manual.
2 Damage resulting from accident, acts of nature or other events beyond the control of
Volvo Trucks North America, Inc.
3 The replacement of expendable maintenance items such as filters, hoses, belts, oil,
thermostat and coolant made in connection with scheduled maintenance services once
these parts have been replaced. Any parts replaced under warranty before the first required replacement point are warranted for the remainder of the warranty period.
4 Replacement items which are not genuine Volvo parts or not authorized by Volvo
Trucks North America, Inc.
5 Loss of time, inconvenience, loss of use of vehicle or engine, or commercial loss.
6 Any vehicle on which the odometer or hourmeter has been disconnected or the
mileage (or hours) has been altered so the actual usage cannot be readily be deter-
mined.
7 Any vehicle registered and normally operated outside the United States.
12 General Information
WHAT IS COVERED BY THE EMISSION WARRANTY
The following is a list of the items that are considered a part of the Emission Control Systems and are covered by the Emission Warranty when installed as original equipment by
Volvo Trucks North America, Inc. on vehicles which were built to conform to Environmental Protection Agency and California Air Resources Board regulations
IMPORTANT - This may not include expendable maintenance items. Emission related
parts requiring scheduled maintenance are warranted until their first scheduled replacement
point.
I. Fuel Injection System
II. Air Induction System
A. Intake Manifold
B. Turbocharge System
C. Charge Air Cooler (Intercooler)
III. Exhaust Manifold
IV. Miscellaneous Items Used in Above Systems
A. Hose, clamps, fittings and tubing
B. Pulleys, belts and idlers
C. Vacuum, temperature, and time sensitive valves and switches
D. Mounting hardware, sealing gaskets and PVC (if applicable)
THIS CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT IN NO WAY
REPLACES, MODIFIES, ALTERS OR SUPERSEDES THE TRUCK WARRANTY CER-
TIFICATE, ITS TERMS AND CONDITIONS, AND ITS
LIMITATIONS AND EXCLUSIONS.
BE CERTAIN YOU READ AND UNDERSTAND ALL WARRANTIES WHICH
ACCOMPANIED YOUR VEHICLE.
NOTE! Warranty coverage is subject to
change without notice. Contact your Volvo
Truck dealer for the current warranty
statement.
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, at the time it left the
control of Volvo Trucks North America,
Inc., with all applicable U.S. EPA Noise
Control Regulations.
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.
General Information 13
14 General Information
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 those acts presumed to constitute
tampering are the acts listed below:
Air Intake System
Removing or rendering inoperative the air
cleaner or intake piping.
Engine Cooling Fan
Removing or rendering inoperative the fan
clutch.
Removing the fan shroud.
Engine
Removing or altering engine speed programming so as to allow engine speed to
exceed manufacturer’s specifications.
Modifying the parameters of the Engine
Electronic Control Unit.
Fuel System
Removing or altering engine speed programming so as to allow engine speed to
exceed manufacturer’s specifications.
Inner Fender Shields and Cab Skirts
Removing shields or skirts.
Cutting away parts of shields, skirts or damaged or loose portions of shields or skirts.
General Information 15
16 General Information
Vehicle Data
Identification and Labels
It is extremely important that the correct
vehicle model and serial number are given
whenever replacement parts or service literature are ordered. Using these numbers, as
well as giving the major component model
and serial numbers, will prevent delay and
errors in obtaining the correct material.
Space is given on the rear inside cover of
this manual for noting the main component
model and serial numbers.
The full 17–digit Vehicle Identification
Number (VIN) is shown on the Vehicle
Identification label located in the door
opening on the driver’s side (see next
page). The 8–digit chassis number is embossed into the bottom flange right hand
side of the frame rail and the top flange left
hand side of the frame rail, 42 inches (1065
mm) back from the front edge of the frame
rail. The use of this number is very helpful
when ordering parts for your vehicle.
Vehicle Order
The Vehicle Order is a complete and detailed record of all data pertaining to the
assembly of the vehicle. It should be filed
in the Owner’s office where it will be readily available for reference. Any changes
made to the vehicle must become a part of
the Vehicle Order and must comply with all
applicable Federal Motor Vehicle Safety
Standards.
W0001995
Identification and Certification Labels
There are two labels that are located on the
rear, lower face of the driver side door
frame. These should be part of the vehicle
at all times.
The VIN is shown on the Vehicle Identification label. The VIN includes the vehicle
make, model series, weight class, engine
model, where the vehicle was built and the
vehicle serial number. This label also
shows the truck model designation, major
component model and serial number, cab
model and serial number, cab and chassis
paint colors, and color numbers.
On the upper part of the door frame is the
Certification label showing the axle and
load ratings for the vehicle as it was built.
Do not exceed these ratings by overloading.
General Information 17
NOTE! To deter tampering with the original build information, the information on
the label will be destroyed if label is
removed. If for any reason a label is damaged, contact your Volvo Truck dealer for a
replacement.
Noise Emission Control
A Noise Emission Control label is located
on the left end of the dash. It is the
Owner’s responsibility to maintain the vehicle so that it conforms to EPA regulations.
Refer to page 14 for a listing of what constitutes tampering with the Noise Emissions
Control.
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W0001458
18 General Information
Components
The Volvo D12 engine serial number is located on the rear, left side of the cylinder
block.
There is also a label on the engine electronic control unit that shows the engine
serial number.
The Volvo D7 engine serial number is located on the rear, left side of the cylinder
block.
There is also a label on the rear valve cover
that shows the engine serial number.
W0001529
W2002707
The rear axle model and serial number is
located on the right side of the transfer gear
housing on the tandem front axle. It is located on the left side of the differential
housing on the tandem rear axle and on the
right side of the single axle.
General Information 19
W4000894
20 Vehicle Access
Cab Doors and Door Lock
The cab door is unlocked with the same
key used for the ignition lock. Keys can be
made to fit only one vehicle or all the vehicles in a fleet of Volvos. A tool for
changing bulbs in the instrument cluster is
included on the keychain.
The key fits in the door lock either way.
Insert the key and turn it 1/4 turn counterclockwise to unlock or clockwise to lock
the door.
NOTE! The vehicle is delivered with 2
identical keys. If more keys are needed,
order them through your Volvo Truck authorized dealer. The keys are laser cut and
require a special machine for copying,
available through the dealer. Record the key
code and keep it in a secure place. A new
key can be made if the keys are lost.
W0001231
Key code at the end of keychain
The door locks are mechanically or electrically operated. The lock is activated by
either the key from the outside or the door
lock handle from the inside. With mechanical locks, only one door can be
locked/unlocked at a time. With electrical
locks, both doors will be locked/unlocked
by operating either the key or the inner
door lock handle on either side.
To lock either door from the inside, push
the door lock handle forward. The handle
will stay in place, indicating the door is
locked. It can be unlocked without opening
the door by moving the door lock handle to
the middle position.
No door can be locked while it is still
open. The door must be closed for the lock
to work. In the event of a power failure the
electrical lock system reverts back to a mechanically functioning system.
W8001462
The door has a position lock that enables
the door to remain open in two different
positions. An indented bar is holding the
door at approximately 30
open position at approximately 85
and in the fully
.
To close the door from the inside, place the
hand in the handhold and pull the door in.
To lessen the chance of being thrown
from the vehicle in case of an accident,
always lock the door and wear the safety
belt while driving. Failure to do so can
cause serious personal injury or death if
involved in an accident.
Vehicle Access 21
W8001854
CAUTION
Do not shut the door by pushing on the
door panel. Hard pushing may distort
the metal in the door panel.
To close the door from the outside, place
the hand flat against the door lock area and
push the door shut.
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22 Vehicle Access
Cab Entry and Exit
General
WARNING
Do not stand on the steps or any other
part of the vehicle while it is in motion.
The steps and the back of cab access
deck plates are only for entering/exiting
the vehicle and not for riding on. Failure
to heed this warning can result in serious personal injury or death.
WARNING
Wearing shoes with soles that are dirty
or wet increases the chance of slipping
and falling. Be careful when entering the
cab with dirty or wet soles.
Both the operator and passenger should
exercise caution when entering or exiting
the cab. Use the steps and grab handles
to safely get in and out of the cab to
prevent injuries related to a slip and fall.
Steps are designed to be slip resistant
and to provide a stable surface for
entering or exiting the cab. However, accumulation of ice, dirt, lubricants, etc.
on the steps can make entering or exiting hazardous. Always make sure the
steps are free from slippery substances.
Failure to follow this guideline may result in a fall that can cause serious
personal injury or death.
The steps on the vehicle are designed to
conform with the requirements of 49 CFR
399. You should familiarize yourself with
this Federal regulation.
W8000928
Vehicle Access 23
General Entry Guidelines
1 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.
2 Be certain you have a firm handhold
and/or stable foot position before
transferring weight to that position. For
example, do not start to put weight on
a foot until you are certain your foot is
properly on the step and will not slip
when you transfer your weight.
3 Do not climb on top of the frame, fuel
tanks or storage boxes to make trailer
hook-ups.
4 If the vehicle is equipped with air fair-
ings, do not use the side mounted
fairing (wind deflector) brackets and
braces as steps or grab handles.
box cover is properly fastened before
stepping.
9 Do not jump from the cab or from the
steps to the ground.
10 Always face the cab when entering or
exiting.
11 Do not hold anything in your hands
when entering or exiting the cab or the
area behind the cab. Log books, cups,
clipboards, jackets, luggage and the
like can be placed on the cab floor or
rear deck plate before entering or exiting.
12 Be sure to disconnect the safety belt
before exiting the cab.
13 Be sure that the safety belt is fully re-
tracted and out of the way prior to
entering or exiting the cab.
5 Be certain that the grab handles are
clear of snow, mud, ice or other substances that could make them slippery
before using them. Do not use steps or
grab handles if they are slippery or
damaged.
6 Be certain that all grab handles, steps
and related parts are in good working
condition. Any defects should be reported and repaired before using the
grab handles and steps.
7 Do not step on the curved surface of
the fuel tanks. They may be slippery
from snow, mud, ice, water, spilled
fuel or other slippery substances.
8 If a step is mounted to the top of the
battery box, be certain that the battery
14 Do not put your foot on any surface
that does not have slip resistant, self
cleaning material. If there is no step
material, the surface may be slippery
and you could fall.
15 Before entering or exiting, be certain
that the soles of your shoes/boots are
free from grease, mud or any other
substance which could make them
slippery.
16 Always put the foot flat on the top of
the step. Do not place your foot on the
side or edge of the step.
BE SURE TO FOLLOW ALL OF
THESE INSTRUCTIONS BEFORE ENTERING O
THE AREA BEHIND THE CAB.
R EXITING THE CAB OR
24 Vehicle Access
Driver Side Entry/Exit
Open the door. Place any hand-carried
items on the cab floor. Grasp the right grab
handle with your right hand and the left
grab handle with your left hand. Put your
right foot fully on the bottom step and pull
yourself up to the opening.
Slide hands up on the handles, if necessary.
Put your left foot on the top step and step
up. Step into the cab with your right foot
first.
To exit, reverse the process. Do not attempt
to exit the cab while carrying any items in
your hands.
WARNING
On vehicles without side fairings, always make sure that the battery box
cover is securely fastened before stepping up. Failure to fasten the cover may
lead to personal injury.
Passenger Side Entry/Exit
Open the door. Place any hand-carried
items on the cab floor. Grasp the left grab
handle with your left hand and the right
grab handle with your right hand. Put your
left foot fully on the bottom step and pull
yourself up to the opening.
Slide hands up on the handles, if necessary.
Put your right foot on the top step and step
up.
W0001223
Step into the cab with your left foot first.
To exit, reverse the process. Do not attempt
to exit the cab while carrying any items in
your hands.
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Behind the Cab Entry
When trailer air and electrical connections
can not be coupled from the ground, Federal Regulations require commercial
carriers to provide back-of-cab access steps,
grab handles and plates.
Depending on what option is chosen, grab
handles are available in many variations. In
each case, make sure to 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 area
behind the cab.
WARNING
Wearing shoes with soles that are dirty
or wet increases the chance of slipping
or falling. Be careful when entering the
back-of-cab area with dirty or wet soles.
Vehicle Access 25
W8001363
Grasp the grab handle to the left with both
hands. Put the left foot onto the bottom
step and pull yourself up. Put the right foot
on the top step and step onto the deck plate
with the left foot.
WARNING
Always perform trailer hook-ups while
standing on the ground. Do not climb
on top of fuel tanks or frame rails to
hook up or disconnect trailer air lines
and electrical cord, or serious injuries
could result from a slip and fall.
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