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Service Manual Trucks 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 de-signs and methods studies carried out up to December 2001. The products are under continuous development. Vehicles and components producedafter the above date may therefore have different speci cations and repair methods.When this is believed to have a signi cant bearing on this manual, supplementary ser-vice 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 ServiceDocumentation: Note: Indicates a procedure, practice, or condition that must be followed in order tohave 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 theproduct 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 inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc.. Contents General ………………………….. 3Preventive Maintenance, General …………………………. 3 Safety Advice …………………………… 7 Speci cations …………………………… 9 Engine ………………………….. 9Transmission ………………………….. 12Rear Axle ……………………. 13 Tools …………………. 14 Special Tools and Special Equipment ……………………. 14 Preventive Maintenance Inspection Bay …………………………… 21 Design and Function ………………….. 23 Clutch …………………………. 23Power Take-off ……………………….. 25Driveshaft ……………………. 25Brakes ………………………… 26Steering System …………………….. 27Hubs ………………………….. 28Chassis ………………………. 29Cab …………………. 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 re-quirements during the Basic Service of Volvo VN/VHDvehicles. The purpose for doing the preventive mainte-nance is to ensure that the vehicle is safe androadworthy over its full lifetime. The driver is taking part in the continuous preventivemaintenance program by completing the required DailyPre-trip Inspection. This is a purely visual inspection thatis designed to detect any obvious problems that wouldmake the vehicle unsafe to take on the road. Added tothe Pre-trip Inspection is the Preventive MaintenanceProgram that is typically carried out by trained personnelusing a systematic approach to cover all important com-ponents of the new vehicle. Preventive Maintenance is a planned vehicle mainte-nance program that provides an orderly series ofservicing and inspecting procedures. A well appliedmaintenance program realizes the investment made inthe vehicle. The difference between a poorly maintainedvehicle and a well maintained vehicle will not show upuntil later mileage. Good maintenance is necessary toassure the designed life expectancy of the vehicle andits individual components. Maintenance Coverage There is no  rm maintenance program that will apply toall operations. A basic maintenance program is not dif -cult to set up; to make the program the most effectivetakes time and effort, and is based around the needsand experiences of each individual operation. The pro-gram in this service manual covers all types of VolvoVN/VHD vehicles with medium to high mileage andsometimes high loads. Use this established maintenance program as a base totailor an individual maintenance program for customersthat have requirements that are outside of the scope ofthis program. To establish an individual program, look at informationsources 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 theprogress in vehicle technology and increases in oil qual-ity to simplify the maintenance. For simpli ed scheduling, the program has tied mainte-nance to logical time or mileage limits that make it easyto anticipate needed servicing. For the majority of on-highway operators, the 24,000 km (15,000 miles) or 4months schedule can be used with little change. It is important that the scheduled intervals are followedas limits. Maintenance can be done before either 24,000km (15,000 miles) have been reached or before 4months are up but must be made at or before either themileage or the time limit has been reached. For further information concerning component speci ca-tions see service information in Group 1,  Oil and FilterChange Intervals for Volvo Components, All Models ,Publication Number 175 001, and any appropriate ven-dor literature. Advantages A well-planned preventive maintenance program offersthe following advantages: The lowest attainable maintenance cost. Maximum vehicle uptime. Better fuel economy. Reduced road failures; greater dependability. Increased customer con dence, 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 mainte-nance program, the success of the program hinges onthe caliber of workmanship in performing the actualinspection. A major cause of failure is a  pencil inspec-tion; that is, the mechanic checks off each operation asbeing OK without making the actual inspection. A  pencilinspection defeats the purpose of the inspection, whichis to detect an impending failure. Maintenance Form A Service Manual is issued detailing the current inspec-tion forms. Forms are created for different users but allwith the same references to this document. When the in-spection point is carried out, check the box if the item isOK. If further work, such as adjustment, repair, etc.,needs to be performed, record this information and goon with the next inspection point. Ite