volvo operator s manual vnl and vnm 2001

Operator's ManualVNL and VNM

ForewordThis manual contains information concerning the safe operation of yourvehicle. It is extremely important that this information is read and un-derstood before the vehicle is operated. This manual also contains aconsiderable amount of information concerning the vehicle, such as ve-hicle identication, Preventive Maintenance recommendations and a logfor your service records. Please keep this in the vehicle at all times. In-formation from other component manufacturers is supplied in separatemanuals in the Owners Package.

NOTE! It is important that this manual stay with the vehicle when it issold. Important safety information must be passed on to the new cus-tomer. The service information contained in this manual gives theowner important information about maintaining the vehicle but is notintended as a substitute for the Preventive Maintenance Service Manualand must not be regarded as such.

The National Highway Trafc Safety Administration (NHTSA) andVolvo Trucks North America, Inc. (VTNA) should be informed imme-diately if you believe that the vehicle has a defect that could cause acrash, injury or death.Contact NHTSA by calling the Auto Safety Hotline at 1 (800) 4249393 (or 3660123 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

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, withoutthe prior written permission of Volvo Trucks North America, Inc..

Order number: PV776-TSP20 154796

ContentsGeneral Information ............................. 1Information For the Owner ................... 1General Safety Information .................. 3Modications to Vehicle ....................... 7Exhaust and Noise Emissions ............... 8Vehicle Data ........................................ 16

Vehicle Access ...................................... 20Cab Doors and Door Lock ................. 20Cab Entry and Exit ............................. 22Luggage Compartment ........................ 29Hood .................................................... 30

Pre-Trip Inspection and Daily Mainte-nance ..................................................... 32General ................................................ 32Pre-Trip Inspection Quick List ........... 33Daily Maintenance .............................. 45

Additional Safety Features ................. 50Safety Belts ......................................... 50SRS Airbag ......................................... 61Safety Equipment ................................ 68VORAD Collision Warning System ... 69

Instruments and Controls ................... 70Dash Overview .................................... 70Instrument Cluster Overview .............. 71Telltale Overview ................................ 72Graphic Display Telltale Overview .... 73Left Instrument Section ...................... 74Main Instrument Section ..................... 82Right Instrument Section .................... 89Changing Telltale Bulbs In Cluster .... 95Steering Column Switches .................. 97Left Switch Cluster ............................. 99Driving Light Switches ..................... 104Right Switch Cluster ......................... 106Pneumatic Switch Cluster ................. 110

Optional Switch Cluster .................... 112Miscellaneous Switches .................... 113

Graphic Display ................................. 114Graphic Display Overview ............... 114Graphic Display Controls ................. 115Graphic Display Telltales .................. 117Information and Stop Messages ....... 118Information Telltale ........................... 119Stop Telltale ...................................... 126Acknowledge Information and StopMessages ........................................... 130Main Menu: Set-Up Mode ............... 132Main Menu: System Diagnostic ....... 137Main Menu: Data Log Mode (VolvoEngine Only) ..................................... 152Main Menu: Password Input ............ 158Main Menu: Gauge ........................... 159Main Menu: Fuel Economy (option) 163Main Menu: Time/Distance .............. 165Main Menu: FAULTS? ..................... 170

Heating and Air Conditioning ......... 174General .............................................. 174Climate Unit Main Control Panel .... 175Sleeper Climate Unit ......................... 183Cab Ventilation .................................. 185Cab Air Filters .................................. 187Parking Heater (optional) .................. 188A/C Diagnostic Module .................... 194

Seats ..................................................... 195General .............................................. 195National Standard Seat Adjustments 196National Comfort Seat Adjustments . 197Volvo Standard Seat Adjustments .... 198Volvo Comfort Seat Adjustments ..... 199National Stationary Seat ................... 202

Cab Interior and Sleeper .................. 203Interior/Reading Lights ..................... 203Storage Compartments ...................... 206Sleeper Bunks ................................... 212VN-660 and VN770 Sleeper Table 217Sleeper Compartment Sink ............... 220Miscellaneous Sleeper Equipment .... 224

Communication and Entertainment 231Antennas ............................................ 231Stereo/Radio ...................................... 233Communication Equipment .............. 234Television .......................................... 235

Fuel Economy Driving ...................... 237Fuel Economy ................................... 237

Engine Start and Operation ............. 244Starting the Engine ........................... 244Cold Weather Start and Operation ... 249Engine Operation .............................. 256Cruise Control ................................... 265Fuel Tank Cap(s) ............................... 267

Clutch and Transmission .................. 269Clutch ................................................ 269Folding Gear Lever (option) ............. 270

Brakes ................................................. 272

Brakes ................................................ 272

Electrical System ............................... 292Electrical System ............................... 292

Power Steering ................................... 309General .............................................. 309

Axles and Wheels ............................... 311Axles .................................................. 311Wheels ............................................... 313

Fifth Wheel Instructions ................... 316Fifth Wheel General Information ..... 316Fifth Wheel ....................................... 319Fifth Wheel Slider (option) .............. 320Unlocking the Fifth Wheel ............... 321Trailer Coupling Procedures ............. 323Trailer Uncoupling Procedures ......... 328Operating the Volvo Slider ............... 333

Emergency Information .................... 335Towing Procedure ............................. 335

Service Information ........................... 341Service Assistance and Manuals ...... 341

Index .................................................... 343

Warning Label InformationIMPORTANT

Before driving this vehicle, be certain that you have read and thatyou fully understand each and every step of the driving and han-dling information in this Operators Manual. Be certain that youfully understand and follow all safety warnings. It is extremely im-portant that this information is read and understood before thevehicle is operated.

IT IS IMPORTANT THAT THE FOLLOW-ING INFORMATION CONCERNINGLABELS BE READ, UNDERSTOODAND ALWAYS FOLLOWED.

The following types of labels are usedthroughout this manual:

NOTE! A note denes an operating proce-dure, practice, condition, etc., which isessential to proper operation of the vehicle.

CAUTIONA caution label directs the operatorsattention to unsafe practices where per-sonal injury is not likely but propertydamage could occur. The caution label isin black type on a white backgroundwith a black border.

WARNINGA warning label directs the operatorsattention to unsafe practices which couldresult in personal injury or severe dam-age to the vehicle. The warning label isin black type on a gray backgroundwith a black border.

A danger label directs the operators at-tention to unsafe practices which couldresult in serious personal injury or death.The caution label is in white type on ablack background with a black border.

General Information 1

Information For the OwnerIf there are questions on the maintenanceand performance of your vehicle, pleasediscuss them with your Volvo Truck dealer.Your authorized dealer is required to havetrained mechanics, special tools and spareparts to fully service your vehicle. Ifnecessary, your dealer will contact the man-ufacturer for any assistance.

In addition to this Operators Manual, theremay be additional instruction/operatorsmanuals supplied by component manufac-turers. These manuals are placed in theOwners Package and placed in the cab. Besure to read all the manuals thoroughly be-fore operating the vehicle.

Also, various safety labels may be placedon components by the component manufac-turer. Be sure to read and follow theselabels to prevent damage to the vehicle,personal injury or even death.Information in this manual refers to Volvocomponents and Volvo drivetrain. Informa-tion concerning non-Volvo engines and/ordrivetrains can be obtained by contactingthe respective manufacturer.

Establish a Preventive Maintenance Pro-gram with the help of your local VolvoTruck dealer. A Preventive MaintenanceProgram makes it possible to maximize theamount of time your vehicle is up and run-ning, resulting in longer component life.This makes for a safer vehicle by reducingany mechanical failures due to poor mainte-nance practices.

Various truck warranty coverage plans, con-tingent on application and weight class, areavailable. Please contact an authorizedVolvo Truck Dealer for complete details.Replacement warranty certicates for VolvoTrucks are available from Volvo dealers.

For trucks placed in service after August 1,2000 and operating in the USA andCanada, Volvo dealers can print copies ofthe Standard Truck Warranty Certicateand the Premium (Purchased) Truck Cover-age Certicate. Copies are available ineither English or Canadian French at thedealer communication system (DCS) web-site. Look in the Service/Warranty folder.

NOTE! Federal law requires manufacturersto notify owners of its products in the eventof a non-compliance to a Federal MotorVehicle Safety Standard or if a safety re-lated defect is discovered. If you are notthe original owner of this vehicle, pleasenotify us about the change in ownership atthe address below or through an authorizedVolvo Truck dealer. This is the only waywe will be able to contact you if necessary.

Volvo Trucks North America, Inc.

Att: Vehicle Registration Dept.

P. O. Box 26115

Greensboro, NC 274026115

United States of America

2 General Information

Do Not Remove this manual from the ve-hicle. It contains important operational andsafety information that is needed by alldrivers and owners of this vehicle.

This Operators Manual covers Volvo VN-series vehicles manufactured by VolvoTrucks North America, Inc. with any of thefollowing designations:

VNL42T VNM42T VNL42 VNM42

VNL64T VNM64T VNL64 VNM64

L=long hood, M=medium hoodT=tractor

Explanation: The rst number after themodel designation represents the total num-ber of wheels (hubs) per vehicle. Thesecond number represents the number ofwheels (hubs) that drive the vehicle. Eachmodel designation also carries a sufx,which identies the cab type.

This manual, together with manuals forspecic components, for example, Volvoengine, Cummins engine, Eaton transmis-sion, etc., contain important information tobe able to operate this vehicle safely. Theycontain advice and instructions which willenable you to get the operating economyand performance that you expect from thisquality vehicle.

All information, illustrations and specica-tions contained in this manual are basedupon the latest product information avail-able at the time of publication. If anyquestions arise concerning the current sta-tus of Federal or state laws, the appropriateFederal or state agency should be contacted.

Volvo Trucks North America, Inc. reservesthe right to make changes at any time or tochange specications or design without no-tice and without incurring obligation.

W0001619

VN cab types


General Safety InformationOperating the VehicleEvery vehicle, including heavy duty vehi-cles, has blind spots. The size of blindspots varies from driver to driver and fromsituation to situation. As a skilled, profes-sional driver, you are in the best position toavoid accidents in turns, lane changes orother maneuvers. Volvo Trucks NorthAmerica, Inc. provides standard equipment(such as cabs, windshields, window sizesand mirrors), preferred by most owners anddrivers under most conditions and in mostapplications.

However, due to differences in the size ofdrivers, their seating positions, the way thatthey use and operate their vehicles, per-sonal preferences and other factors, nocombination of mirrors and other visibilityenhancement devices will eliminate allblind spots in every situation.

The safe operation of this vehicle is up toyou. Because of your special preferences,needs and circumstances, you may want toadd extra mirrors and/or other visibility en-hancement devices. If so, you shouldcontact an authorized Volvo Truck dealer toobtain those parts which best t your ownpersonal needs and preferences.

WARNINGAll items within the cab must be securedbefore the vehicle is set in motion. Thisincludes, but is not limited to, drinks,clothes, books, televisions, etc. In theevent of a collision, loose items couldy around inside the cab. This couldcause personal injury.

Never try to operate or work on thisvehicle while under the inuence of al-cohol. Your reexes can be affected byeven a small amount of alcohol. Drink-ing and operating this vehicle can leadto an accident, causing serious personalinjury or death.


Operating In Bobtail ModeTractors are equipped with a bobtail airbrake proportioning valve which automati-cally redistributes the braking force betweenfront and rear axles when not hooked up toa semitrailer (bobtail operation).When operating in bobtail mode, the rearbrake chambers receive reduced or propor-tional brake air pressure. When the tractoris towing a trailer, the rear brake chamberswill receive full (normal) brake pressure.NOTE! When operating bobtail, be certainthat glad hands, trailer air hoses, electricalcable and connectors are properly stowedand secure. Do not allow them to rub orchafe on other components.

WARNINGWhen operating bobtail, the brakesystem on the vehicle reduces the possi-bility of rear wheel brake lockup, excepton full pedal application. When bobtail-ing, be certain that adequate pedalpressure is applied. There is no need toreduce pedal effort. Failure to do so mayresult in increased stopping distances.


Do Not OverloadThis vehicle has been designed and assem-bled for a maximum gross vehicle weightrating (GVWR) and a maximum front andrear axle weights rating (FAWR andRAWR). The actual rating for this vehiclecan be found on the label attached to thedoor frame on the drivers side. If any ofthese three ratings is exceeded and over-loading occurs, instability, poor handling,failure of parts and accelerated wear canoccur.

Under no circumstances should the pub-lished GVWR, FAWR, and/or RAWR beexceeded. Failure to observe these pre-cautions can lead to the loss of vehiclecontrol, resulting in a crash causing seri-ous personal injury or death.

Do not exceed the load rating of thetires or the vehicle weight ratings. Over-loading may result in tire failure causingloss of vehicle control, leading to an ac-cident resulting in severe personal injuryor death.

W0001210

OperatingBefore driving this vehicle, locate the in-struments and controls, and becomethoroughly familiar with their operation.After starting and when driving, alwayscheck to make sure that the instrumentreadings are normal.


Reporting Safety DefectsUSAThe National Highway Trafc Safety Ad-ministration (NHTSA) and Volvo TrucksNorth America, Inc. should be informedimmediately if you believe that the vehiclehas a defect that could cause a crash, injuryor death.

Contact NHTSA by calling the Auto SafetyHotline at 1 (800) 4249393 (or 3660123in the Washington, DC area) or by writingto: NHTSA, U. S. Department of Trans-portation, Washington, DC 20590.

1 (800) 424-9393

CanadaRefer consumer complaints to Volvo TrucksCanada, Inc. or to the Transport Canada -Department of Public Complaints, Recallsand Investigations.

1 (905) 795-1555MexicoVolvo Trucks of Mexico, S.A. de C.V.should be informed immediately if you be-lieve the vehicle has a defect that couldcause a crash, injury or death. ContactVolvo Trucks de Mexico by calling or bywriting to: Volvo Trucks de Mexico, S.A.de C.V., Prol. Paseo de la Reforma 600,1er. Piso 121, Col. Santa Fe PeaBlanca, C.P. 01210, Mxico, D.F.

01 (800) 90 94 900

NOTE! For a listing of other contacts forinformation or help, see page 341.


Modications to VehicleChassis FrameFrame side rails are heat treated. No weld-ing is permitted because structural failuremay result. Do not drill through either topor bottom anges. A warning label is alsoattached to the frame for information.

Drilling is permitted in the frame web inaccordance with a specied hole spacingpattern. Consult a Volvo Truck dealer toobtain approved hole spacing dimensions orrefer to the Frame Rail and Cross MemberService Manual.

Frame rail and cross member nuts and boltsshould be checked periodically and tight-ened to the specied torque if necessary.

W7000519

WARNINGDo not weld on any part of the frame ordrill holes in the top or bottom anges.Serious structural damage could occur.

Frame AlterationsUnder no circumstances can the frame becut and an extension piece added to in-crease the wheelbase. The only alterationallowed is wheel base shortening, wherethe only change in the frame rail is a newhole pattern drilled for the new location ofthe rear suspension.

Welding In VehicleDo not weld anywhere in or on the vehiclebefore disconnecting batteries, all electroniccontrol units (ECU) and instrument cluster.See page 298 for more information. Do notuse oxy/acetylene welding to repair cabpanels. Refer to the service manuals forspecic information.


Exhaust and Noise EmissionsGeneralUSAThe Federal Clean Air Act, Section 203 (a)(3), states the following concerning the re-moval of air pollution control devices ormodication of a certied engine to a non-certied conguration:

The following acts and the causing thereofare prohibited:

(3) For any person to remove or render in-operative any device or element of designinstalled on or in a motor vehicle or motorvehicle engine in compliance with regula-tions under this part prior to its sale anddelivery to the ultimate purchaser, or forany manufacturer or dealer knowingly toremove or render inoperative any such de-sign after sale and delivery to the ultimatepurchaser.

Specically, please note that no person maymake such changes prior to the sale and

delivery of the vehicle to the ultimate pur-chaser, and, in addition, no manufacturer ordealer may make take such action after saleand delivery of the vehicle to the ultimatepurchaser. The law provides a penalty of upto $10,000 for each violation.

Modications, such as reprogramming ofthe fuel system so the engine will exceedthe certied horsepower or torque, or re-moving the mufers are examples of illegalchanges.

Changes should not be made to a certiedengine that would result in an engine thatdoes not match the conguration of an en-gine model that is currently certied tomeet Federal Standards.

CanadaThe same conditions that apply in the USAapply to Canada, with one exception. Afterthe vehicle is sold to a retail customer, thatis, the end user, the jurisdiction controllingthe emission control devices becomes theprovince in which the vehicle is licensed.No changes should be made that render anyor all of the devices inoperative.

Should the owner/operator wish to makeany changes to the emission control de-vices, check with the provincial authoritybefore making any such changes.

MexicoThe same conditions that apply in the USAapply to Mexico. Refer to the MexicanFederal Law for Emission Control whichadheres to EPA regulations. No changesshould be made that render any or all ofthe emissions control devices inoperative.

Should the owner/operator wish to makeany changes to the emission control de-vices, check with the state authority beforemaking any such changes.


California Emission Control Warranty StatementYOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Volvo Trucks North America , Inc. (VTNA) arepleased to explain the emission control system warranty on your vehicle. In California,new motor vehicles must be designed, built and equipped to meet the States stringentanti-smog standards. Volvo Trucks North America, Inc. must warrant the emission controlsystem on your vehicle for the periods of time listed below provided there has been noabuse, neglect or improper maintenance of your vehicle.

Your emission control system may include parts such as carburetor or fuel injection systemand engine computer. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Volvo Trucks North America, Inc. will repair yourvehicle at no cost to you including diagnosis, parts and labor.

MANUFACTURERS WARRANTY COVERAGEThis warranty is appliccable for a period of ve years, 100,000 miles or 3,000 hours ofoperation, whichever rst 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.

OWNERS WARRANTY RESPONSIBILITIES

As the vehicle owner, you are responsible for the performance of the required maintenancelisted in your owners manual. Volvo Trucks North America, Inc. recommends that you re-tain 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 per-formance 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 reason-able 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 modications.

If you have any questions regarding your warranty rights and responsibilities, you shouldcontact Volvo Trucks North America, Inc., Warranty Administration, (336) 393-2000 orthe California Air Resources Board at 9480 Telstar Avenue, El Monte, CA 91731.


EMISSION CONTROL SYSTEM WARRANTY

Volvo Trucks North America, Inc. WARRANTS TO THE ORIGINAL OWNER, ANDEACH SUBSEQUENT OWNER, OF A NEW TRUCK POWERED BY A VOLVODIESEL 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 regulationsof the U.S. Environmental Protection Agency and the California Air Resources Boardapplicable 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 100,000miles or 3,000 hours of engine operation, whichever comes rst.

The 5 years/100,000 miles/3,000 hour warranty period shall begin on the date the vehicleis rst delivered to the rst retail purchaser or if the vehicle is placed in service as ademonstrator company vehicle prior to the sale at retail, on the date the vehicle is the rstplaced in service.

The emission control system of your new Volvo engine was designed, built and tested us-ing genuine Volvo parts, and the engine is certied as being in conformity with Federaland California emission control regulations. Accordingly, it is recommended that any re-placement parts used for maintenance, replacement or repair without invalidating thiswarranty; the cost of such services or or parts, however, will not be covered under the war-ranty except in an emergency situation. A part not being available or a repair not beingcompleted within 30 days also constitutes an emergency.

Use of replacement parts which are not of equivalent quality may impair the effectivenessof emission control systems. If other than Volvo parts are used for maintenance, ownershould obtain assurances that suck parts are warranted by their manufacturer to be equiva-lent to genuine Volvo parts. However, the use of other than Volvo replacement parts doesnot invalidate the warranty on other components, unless such parts cause damage to war-ranted parts.

Repairs and service covered by the warranty will be performed by an authorized VolvoTrucks North America, Inc. dealer at his place of business with no charge for parts or la-bor (including diagnosis) using Volvo parts for the emission control system, that requiresreplacement 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 maybe performed at any available service establishment or by the owner, using any equivalentreplacement parts and Volvo Trucks North America, Inc. will reimburse the owner for suchrepairs (including diagnosis) not to exceed Volvo Trucks North America, Incs suggestedretail retail price for the warranted parts and the labor rate appropriate for the geographicalarea and the tasks performed.

Replaced parts and paid invoices must be presented to a Volvo Trucks North America, Inc.dealer for reimbursement.


The emissions control parts covered by this Emission Control System Warranty are listedunder "What Is Covered by the Emissions Warranty." You are responsible for the perfor-mance of all required maintenance on your new Volvo engine, including maintenance orrepairs needed due to severe operating conditions. Volvo Trucks North America, Inc. willnot 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 performrequired maintenance resulted in the failure of a warranted part. Receipts covering theperformance of regular maintenance should be retained in the event questions arise con-cerning maintenance. The receipts should be transferred to each subsequent owner of thevehicle with the emission warranted engine.

CUSTOMER ASSISTANCEVolvo Trucks North America, Inc. wishes to help to assure that the Emission Control Sys-tem Warranty is properly administered. In the event that you do not receive the warrantyservice 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 Ofce is in your vehicleowners manual. If you need additional assistance or information concerning the EmissionControl System Warranty, contact: Volvo Trucks North America, Inc., Warranty Adminis-tration, (336) 393-2000.

WHAT IS NOT COVERED BY THE EMISSION WARRANTYThis warranty does not cover:

1 Malfunctions in any part caused by any of the following: misuse, abuse, improperadjustments unless performed by a Volvo Trucks North America, Inc. dealer, modi-cations, alterations, tampering, disconnection, improper or inadequate maintenance, oruse of fuels not recommended for the engine as described in the owners manual.

2 Damage resulting from accident, acts of nature or other events beyond the control ofVolvo Trucks North America, Inc.

3 The replacement of expendable maintenance items such as lters, hoses, belts, oil,thermostat and coolant made in connection with scheduled maintenance services oncethese parts have been replaced. Any parts replaced under warranty before the rst re-quired replacement point are warranted for the remainder of the warranty period.

4 Replacement items which are not genuine Volvo parts or not authorized by VolvoTrucks 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.


WHAT IS COVERED BY THE EMISSION WARRANTY

The following is a list of the items that are considered a part of the Emission Control Sys-tems and are covered by the Emission Warranty when installed as original equipment byVolvo Trucks North America, Inc. on vehicles which were built to conform to Environ-mental Protection Agency and California Air Resources Board regulations

IMPORTANT - This may not include expendable maintenance items. Emission relatedparts requiring scheduled maintenance are warranted until their rst scheduled replacementpoint.

I. Fuel Injection SystemII. 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, ttings 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 WAYREPLACES, MODIFIES, ALTERS OR SUPERSEDES THE TRUCK WARRANTY CER-

TIFICATE, ITS TERMS AND CONDITIONS, AND ITSLIMITATIONS AND EXCLUSIONS.

BE CERTAIN YOU READ AND UNDERSTAND ALL WARRANTIES WHICHACCOMPANIED YOUR VEHICLE.

NOTE! Warranty coverage is subject tochange without notice. Contact your VolvoTruck dealer for the current warrantystatement.


Noise EmissionsVolvo Trucks North America, Inc. warrantsto the rst person who purchases this vehi-cle for purposes other than resale and toeach subsequent purchaser, that this vehicleas manufactured by Volvo Trucks NorthAmerica, Inc. was designed, built andequipped to conform, at the time it left thecontrol of Volvo Trucks North America,Inc., with all applicable U.S. EPA NoiseControl Regulations.

This warranty covers this vehicle as de-signed, built and equipped by Volvo TrucksNorth America, Inc., and is not limited toany particular part, component or system ofthe vehicle manufactured by Volvo TrucksNorth America, Inc. Defects in design, as-sembly or in any part, component or systemof the vehicle as manufactured by VolvoTrucks North America, Inc., which, at thetime it left the control of Volvo TrucksNorth America, Inc. caused noise emissionsto exceed Federal standards, are covered bythis warranty for the life of the vehicle.


Tampering with Noise Control SystemFederal law prohibits the following acts orthe causing thereof:

(1) The removal or rendering inoperative byany person, other than for purposes ofmaintenance, repair, or replacement, of anydevice or element of design incorporatedinto any new vehicle for the purpose ofnoise control prior to its sale or delivery tothe ultimate purchaser or while it is in use;

or

(2) the use of the vehicle after such deviceor element of design has been removed orrendered inoperative by any person.

Among those acts presumed to constitutetampering are the acts listed below:

Air Intake SystemRemoving or rendering inoperative the aircleaner or intake piping.

Engine Cooling FanRemoving or rendering inoperative the fanclutch.

Removing the fan shroud.

EngineRemoving or altering engine speed pro-gramming so as to allow engine speed toexceed manufacturers specications.

Modifying the parameters of the EngineElectronic Control Unit.


Fuel SystemRemoving or altering engine speed pro-gramming so as to allow engine speed toexceed manufacturers specications.

Inner Fender Shields and Cab SkirtsRemoving shields or skirts.

Cutting away parts of shields, skirts or dam-aged or loose portions of shields or skirts.


Vehicle DataIdentication and LabelsIt is extremely important that the correctvehicle model and serial number are givenwhenever replacement parts or service liter-ature are ordered. Using these numbers, aswell as giving the major component modeland serial numbers, will prevent delay anderrors in obtaining the correct material.Space is given on the rear inside cover ofthis manual for noting the main componentmodel and serial numbers.

The full 17digit Vehicle IdenticationNumber (VIN) is shown on the VehicleIdentication label located in the dooropening on the drivers side (see nextpage). The 8digit chassis number is em-bossed into the bottom ange right handside of the frame rail and the top ange lefthand side of the frame rail, 42 inches (1065mm) back from the front edge of the framerail. The use of this number is very helpfulwhen ordering parts for your vehicle.

W0001995

Vehicle OrderThe Vehicle Order is a complete and de-tailed record of all data pertaining to theassembly of the vehicle. It should be ledin the Owners ofce where it will be read-ily available for reference. Any changesmade to the vehicle must become a part ofthe Vehicle Order and must comply with allapplicable Federal Motor Vehicle SafetyStandards.


Identication and Certication LabelsThere are two labels that are located on therear, lower face of the driver side doorframe. These should be part of the vehicleat all times.

The VIN is shown on the Vehicle Identi-cation label. The VIN includes the vehiclemake, model series, weight class, enginemodel, where the vehicle was built and thevehicle serial number. This label alsoshows the truck model designation, majorcomponent model and serial number, cabmodel and serial number, cab and chassispaint colors, and color numbers.

On the upper part of the door frame is theCertication label showing the axle andload ratings for the vehicle as it was built.Do not exceed these ratings by overloading.

NOTE! To deter tampering with the origi-nal build information, the information onthe label will be destroyed if label isremoved. If for any reason a label is dam-aged, contact your Volvo Truck dealer for areplacement.

W0001210

Noise Emission ControlA Noise Emission Control label is locatedon the left end of the dash. It is theOwners responsibility to maintain the vehi-cle so that it conforms to EPA regulations.

Refer to page 14 for a listing of what con-stitutes tampering with the Noise EmissionsControl.

W0001458


ComponentsThe Volvo D12 engine serial number is lo-cated on the rear, left side of the cylinderblock.

There is also a label on the engine elec-tronic control unit that shows the engineserial number.

W0001529

The Volvo D7 engine serial number is lo-cated on the rear, left side of the cylinderblock.

There is also a label on the rear valve coverthat shows the engine serial number.

W2002707


The rear axle model and serial number islocated on the right side of the transfer gearhousing on the tandem front axle. It is lo-cated on the left side of the differentialhousing on the tandem rear axle and on theright side of the single axle.

W4000894

20 Vehicle Access

Cab Doors and Door LockThe cab door is unlocked with the samekey used for the ignition lock. Keys can bemade to t only one vehicle or all the vehi-cles in a eet of Volvos. A tool forchanging bulbs in the instrument cluster isincluded on the keychain.

The key ts in the door lock either way.Insert the key and turn it 1/4 turn counter-clockwise to unlock or clockwise to lockthe door.

NOTE! The vehicle is delivered with 2identical keys. If more keys are needed,order them through your Volvo Truck au-thorized dealer. The keys are laser cut andrequire a special machine for copying,available through the dealer. Record the keycode and keep it in a secure place. A newkey can be made if the keys are lost.

The door locks are mechanically or electri-cally operated. The lock is activated byeither the key from the outside or the doorlock handle from the inside. With mechani-cal locks, only one door can belocked/unlocked at a time. With electricallocks, both doors will be locked/unlockedby operating either the key or the innerdoor lock handle on either side.

W0001231

Key code at the end of keychain

To lock either door from the inside, pushthe door lock handle forward. The handlewill stay in place, indicating the door islocked. It can be unlocked without openingthe door by moving the door lock handle tothe middle position.

No door can be locked while it is stillopen. The door must be closed for the lockto work. In the event of a power failure theelectrical lock system reverts back to a me-chanically functioning system.

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Vehicle Access 21

The door has a position lock that enablesthe door to remain open in two differentpositions. An indented bar is holding thedoor at approximately 30 and in the fullyopen position at approximately 85.

To close the door from the inside, place thehand in the handhold and pull the door in.

To lessen the chance of being thrownfrom the vehicle in case of an accident,always lock the door and wear the safetybelt while driving. Failure to do so cancause serious personal injury or death ifinvolved in an accident.

W8001854

CAUTIONDo not shut the door by pushing on thedoor panel. Hard pushing may distortthe metal in the door panel.

To close the door from the outside, placethe hand at against the door lock area andpush the door shut.

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22 Vehicle Access

Cab Entry and ExitGeneral

Do not stand on the steps or any otherpart of the vehicle while it is in motion.The steps and the back of cab accessdeck plates are only for entering/exitingthe vehicle and not for riding on. Failureto heed this warning can result in seri-ous personal injury or death.

WARNINGWearing shoes with soles that are dirtyor wet increases the chance of slippingand falling. Be careful when entering thecab with dirty or wet soles.

WARNINGBoth the operator and passenger shouldexercise caution when entering or exitingthe cab. Use the steps and grab handlesto safely get in and out of the cab toprevent injuries related to a slip and fall.

Steps are designed to be slip resistantand to provide a stable surface forentering or exiting the cab. However, ac-cumulation of ice, dirt, lubricants, etc.on the steps can make entering or exit-ing hazardous. Always make sure thesteps are free from slippery substances.Failure to follow this guideline may re-sult in a fall that can cause seriouspersonal injury or death.

The steps on the vehicle are designed toconform with the requirements of 49 CFR399. You should familiarize yourself withthis Federal regulation.

W8000928

Vehicle Access 23

General Entry Guidelines1 Always have three limbs (one foot and

two hands or two feet and one hand)in contact with the vehicle at all timeswhen entering or exiting the cab or thearea behind the cab.

2 Be certain you have a rm handholdand/or stable foot position beforetransferring weight to that position. Forexample, do not start to put weight ona foot until you are certain your foot isproperly on the step and will not slipwhen you transfer your weight.

3 Do not climb on top of the frame, fueltanks or storage boxes to make trailerhook-ups.

4 If the vehicle is equipped with air fair-ings, do not use the side mountedfairing (wind deector) brackets andbraces as steps or grab handles.

5 Be certain that the grab handles areclear of snow, mud, ice or other sub-stances that could make them slipperybefore using them. Do not use steps orgrab handles if they are slippery ordamaged.

6 Be certain that all grab handles, stepsand related parts are in good workingcondition. Any defects should be re-ported and repaired before using thegrab handles and steps.

7 Do not step on the curved surface ofthe fuel tanks. They may be slipperyfrom snow, mud, ice, water, spilledfuel or other slippery substances.

8 If a step is mounted to the top of thebattery box, be certain that the battery

box cover is properly fastened beforestepping.

9 Do not jump from the cab or from thesteps to the ground.

10 Always face the cab when entering orexiting.

11 Do not hold anything in your handswhen entering or exiting the cab or thearea behind the cab. Log books, cups,clipboards, jackets, luggage and thelike can be placed on the cab oor orrear deck plate before entering or exit-ing.

12 Be sure to disconnect the safety beltbefore exiting the cab.

13 Be sure that the safety belt is fully re-tracted and out of the way prior toentering or exiting the cab.

14 Do not put your foot on any surfacethat does not have slip resistant, selfcleaning material. If there is no stepmaterial, the surface may be slipperyand you could fall.

15 Before entering or exiting, be certainthat the soles of your shoes/boots arefree from grease, mud or any othersubstance which could make themslippery.

16 Always put the foot at on the top ofthe step. Do not place your foot on theside or edge of the step.

BE SURE TO FOLLOW ALL OFTHESE INSTRUCTIONS BEFORE EN-TERING OR EXITING THE CAB ORTHE AREA BEHIND THE CAB.

24 Vehicle Access

Driver Side Entry/ExitOpen the door. Place any hand-carrieditems on the cab oor. Grasp the right grabhandle with your right hand and the leftgrab handle with your left hand. Put yourright foot fully on the bottom step and pullyourself up to the opening.

Slide hands up on the handles, if necessary.Put your left foot on the top step and stepup. Step into the cab with your right footrst.

To exit, reverse the process. Do not attemptto exit the cab while carrying any items inyour hands.

WARNINGOn vehicles without side fairings, al-ways make sure that the battery boxcover is securely fastened before step-ping up. Failure to fasten the cover maylead to personal injury.

W0001223

Passenger Side Entry/ExitOpen the door. Place any hand-carrieditems on the cab oor. Grasp the left grabhandle with your left hand and the rightgrab handle with your right hand. Put yourleft foot fully on the bottom step and pullyourself up to the opening.

Slide hands up on the handles, if necessary.Put your right foot on the top step and stepup.

Step into the cab with your left foot rst.

To exit, reverse the process. Do not attemptto exit the cab while carrying any items inyour hands.

W0001228

Vehicle Access 25

Behind the Cab EntryWhen trailer air and electrical connectionscan not be coupled from the ground, Fed-eral Regulations require commercialcarriers to provide back-of-cab access steps,grab handles and plates.

Depending on what option is chosen, grabhandles are available in many variations. Ineach case, make sure to always have threelimbs (one foot and two hands or two feetand one hand) in contact with the vehicle atall times when entering or exiting the areabehind the cab.

WARNINGWearing shoes with soles that are dirtyor wet increases the chance of slippingor falling. Be careful when entering theback-of-cab area with dirty or wet soles.

W8001363

Grasp the grab handle to the left with bothhands. Put the left foot onto the bottomstep and pull yourself up. Put the right footon the top step and step onto the deck platewith the left foot.

WARNINGAlways perform trailer hook-ups whilestanding on the ground. Do not climbon top of fuel tanks or frame rails tohook up or disconnect trailer air linesand electrical cord, or serious injuriescould result from a slip and fall.

W9000077

26 Vehicle Access

Stand on the ground when connecting theair and electrical connections to the trailer.

W5000713

Entering Sleeper From SeatStandard Gear LeverWhen moving from the driver seat to thesleeper section, follow this procedure:

Make sure the parking brakes are set

Place the gear shift lever in a gear po-sition toward the rear of the vehicle

If equipped with an adjustable steeringcolumn, move the steering wheel upand forward

Place the left hand on the steeringwheel and the right hand on the top ofthe gear lever

Move the right foot out to the middleof the oor

Lift the upper body, supported by thehands on the steering wheel and thegear lever and step out from the seatarea.

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Vehicle Access 27

Folding Gear Lever (option)When moving from the driver seat to thesleeper section, follow this procedure:

Make sure the parking brakes are set

To release the gear lever, pull the levertoward the seat and press on the knobdownward in a straight line.

W4001388

Twist the lever counterclockwise whileholding pressure on the knob. Whenreleasing the pressure, thespringloaded lever will be pushed upout of the locked position.

W4001389

Lift and fold the gear lever straightback, parallel with the seat. It willcome to rest in the folded position.

NOTE! If the lever is not foldedstraight back, it may not be able totravel the full distance.

W4001390

28 Vehicle Access

If equipped with an adjustable steeringcolumn, move the steering wheel upand forward

Place the left hand on the steeringwheel and the right hand on the top ofthe dash

Move the right foot out to the middleof the oor

Lift the upper body, supported by thehands on the steering wheel and thedash and step out from the seat area.

When locking the gear lever in placeagain, follow the procedure on page 271.Failure to lock the gear lever properlyinto place can cause loss of control ofvehicle, leading to serious personal in-jury or death. W4001391

Vehicle Access 29

Luggage CompartmentTo gain access to the luggage compart-ments, there is a pull-ring connected to thelock, located at the lower rear corner of thecab door opening on each side. Pull ring tounlock the door. The lock has a safety catchthat will hold the door in place, even if thedoor is not fully locked. To open door, holdpull-ring out while pulling the door out.

W8000984

The door swings out from the bottom onhinges mounted on the top. To assist inopening and to hold the door open, thereare two compressed gas cylinders mountedon each door. The door will swing up by it-self when pulled out a short distance andthen released. If the light switch is set onautomatic, the light will come on when thedoor opens.

W8001073

Safety equipment and tow hooks are storedin the luggage compartments. If equipped,the sleeper heater and air conditioning unitis located in the passenger side luggagecompartment.

WARNINGAlways place heavy objects in the lug-gage compartment. Sudden stops orsudden turns could cause personal injuryif heavy objects fall from overhead stor-age shelves.

W1000139

30 Vehicle Access

HoodThe hood is locked down by two latches,one on each side of the back end of thehood. The latches are operated by a handleon the bottom edge of the dashboard.

Pull the bottom of the handle out to releasehood. The hood will be raised about twoinches off its resting position and remainthere.

Make sure the hood can be opened fullywithout hitting anything. Stand sideways infront of the hood with feet in line with thevehicle. Place feet well apart and grasp therecessed handle in the front part of thehood. Transfer the body weight by leaningaway from the hood. Lift the hood until itis past the balance point. Release the hoodand let it complete the opening movementunaided.

Two restraint cylinders will engage duringthe last part of the opening. The cylinderswill slow and dampen the hood down to itsresting position.

WARNINGMake sure that no one is in the way ofthe hood when closing. The hood couldinjure a person in the way while beinglowered.

To close the hood, stand with feet wellapart and place the hands along the frontedge of the hood. Bend the knees and letthe leg muscles do the work when lifting.

Raise the hood up to the halfway point.Carefully guide the hood down withenough speed that the hood latches lock thehood in place when it comes to its normalresting position.

W8000986

W8000982

W8000983

Vehicle Access 31

Manual Hood OpeningIn the event of a malfunction in the hoodopening mechanism, the hood latches canbe manually operated through an openingin the wheelwell splash shield. The openingis normally covered by a plate.

To access the opening, remove the twoscrews using a T30 Torx screwdriver. Re-move the cover plate.

W8002389

The hood latch can now be accessedthrough the hole. Operate the latch manu-ally by pushing the lever in toward theengine. Do the same on the other side.

W8000981

32 Pre-Trip Inspection and Daily Maintenance

General

Before working on or inspecting a vehi-cle, set the parking brakes, place thetransmission in neutral and block thewheels. Failure to do so can result in un-expected vehicle movement and cancause serious personal injury or death.

Safety is the most important and obviousreason for doing a pre-trip inspection. Fed-eral and state laws require inspection doneby the driver. Federal and state inspectorsalso inspect commercial vehicles. An un-safe vehicle can be placed out of serviceuntil the driver or owner corrects thedeciency. Owners and operators should fa-miliarize themselves with sections 49 CFR396.11 and 396.13 concerning Federal re-quirements for vehicle inspection. Certainother laws may also apply.

Section 49 CFR 396.13 states that all motorcarrier drivers must complete a written re-port at the end of each work day for eachvehicle operated, covering most of what iscovered in the pre-trip list. The reportshould list all defects or deciencies dis-covered by the driver. Doing a pre-tripinspection prepares for the end-of-work re-port.

Starting on the next page are suggestedguidelines to be used in performing truck,tractor and trailer pre-trip inspections. De-

pending on the application of the vehiclebeing used, these guidelines should bemodied to include other necessary inspec-tion points. For example, steps and grabhandles should be checked daily on refusetrucks because the operator is getting inand out of the cab more frequently.

If any component or system does not passthis inspection, it must be corrected beforeoperating the vehicle. Whenever equipmentrequires adjustment, replacement, repair orlubrication, refer to the Service Manuals orcontact a Volvo Truck dealer for the correctprocedures, specications and intervals.

Take your time going through the pre-tripinspection. Remember that a careful pre-tripinspection saves time by eliminating un-scheduled stops for correcting a faulty item.

The following information has beenprovided by the American Trucking Associ-ation as developed by the D.O.T. Ofce ofMotor Carriers (BMCS).

Pre-Trip Inspection and Daily Maintenance 33

Pre-Trip Inspection Quick List

W0001230

Inspect the vehicle in a circular manner as shown in theillustration. Numbers between parentheses in the list, re-fer to pages in this manual where component functionand necessary inspection is explained in greater detail.

Approaching the Vehicle

Check under the vehicle for oil, fuel,coolant leaks or other signs of damage.

Check body surfaces for signs ofbreaks or damage.

Preparation

Open drain cocks on air tanks to letthe tanks drain ( page 283).

Chock wheels on vehicle and, ifhooked up, trailer.

Close air tank drain cocks.

Start the engine and let the air pres-sure build up to normal ( page 273).Stop engine.

Switch on parking lights and four-wayashers ( page 99).

Apply parking brakes ( page 278). Release the hood latches ( page 30).

Raise hood.

Step 1: Left Side Of the Cab

Left Front Wheel

Check condition of wheel rim. Espe-cially look for cracks, missinglockrings, bent or broken studs,clamps or lugs.

Check condition of tire: properly in-ated, no serious cuts, bulges, treadwear or any signs of misalignment;valve stem not touching wheel, rim orbrake drum; valve cap in place.

Check wheel bearing and hub: no ob-vious leaking on outside or insidewheel. Verify correct oil level in hub.

Left Front Suspension

Check condition of spring, springhangers, shackles, U-bolts: no cracks,breaks or shifting.

Check shock absorber condition.


Step 1: Left Side Of the Cab (cont.)Left Front Brake Condition of brake drum. With brakes

released, look for a noticeable gap be-tween lining and drum (This checkcannot be made if dust covers are inplace).

Condition of brake air hose.

Check brake chamber mounting boltsand bracket.

Check slack adjuster and chamberpushrod travel.

Condition of Front Axle and Steering Sys-tem, Left Side No loose, worn, bent, damaged or

missing parts.

Under Hood, Left Side Check coolant hose condition.

Check condition of fan drive belts.

Check engine and surrounding areasfor coolant, oil and fuel leaks.

Check wiring harnesses for signs ofdamage.

Step 2: Front Of Cab Area

Condition of Windshield Check for damage and clean if dirty

( page 48 ). Check windshield wiper arms for

proper spring tension.

Check wiper blades for any damage,dead rubber and securement to arm.

Lights and Reectors

Lower hood and inspect parking,clearance and identication lights onhood and cab. They should be clean,operating and of the proper color.

Reectors clean and proper color.

Turn on headlights. High and lowbeams should be operating and lensesclean. If equipped, check daytime run-ning lights.

Left and right front turn signal lightsclean, operating and proper color.Raise hood.

Grille

Check that charge air cooler and radia-tor or bugscreens are clean andundamaged.

Step 3: Right Side Of Cab Area

Right Front Wheel

Check condition of wheel rim. Espe-cially look for cracks, missinglockrings, bent or broken studs,clamps or lugs.

Check condition of tire: properly in-ated, no serious cuts, bulges, treadwear or any signs of misalignment;valve stem not touching wheel, rim orbrake drum; valve cap in place.

Check wheel bearing and hub: no ob-vious leaking on outside or insidewheel. Verify correct oil level in hub.


W0001230

Step 3: Right Side Of Cab Area (cont.)Right Front Suspension

Check condition of spring, springhangers, shackles, U-bolts: no cracks,breaks or shifting.

Shock absorber condition.

Right Front Brake

Condition of brake drum. With brakesreleased, look for a noticeable gap be-tween lining and drum (This checkcannot be made if dust covers are inplace).

Condition of brake air hose: check forany chang.

Check brake chamber mounting boltsand bracket.

Check slack adjuster and chamberpushrod travel. With brakes applied orreleased, look for conspicuously dif-ferent positions of the slack adjusters.

Condition of Front Axle and Steering Sys-tem, Right Side

No loose, worn, bent, damaged ormissing parts.

Under Hood, Right Side

Check condition of coolant and heaterhoses.

Check condition of fan drive belts.

Check engine and surrounding areasfor coolant, oil and fuel leaks.

Check fuel separator sight glass anddrain if necessary. Check for leaks.

Check wiring harnesses for signs ofdamage.

Check air lter with brackets andhoses for loose connections or dam-age. Check lter gauge, if mounted onthe lter.

Step 4: Right Saddle Tank Area

Right Fuel Tank(s)

Securely mounted and not damaged orleaking.

Fuel lines secure and not leaking.Check that shut-off valves are open.

Tank(s) full of fuel. Cap on and secure.


Condition of Visible Components

Rear of engine: not leaking.

Transmission: not leaking. If equippedwith oil cooler, check for leaks or thatair-to-air cooler is not blocked.

Check drive shaft.

Exhaust system: secure, not leaking,not touching wires, fuel or air tubing.

Frame and cross members: no bends,cracks or breaks.

Air tubing and electrical wiring: se-cured against snagging and chang.

Step 5: Right Rear Vehicle Area

Dual Wheels, One Or Two Axles

Check condition of wheels and rims.Especially look for cracks, missinglockrings, bent or broken spacers,studs, clamps or lugs.

Check condition of tires: properly in-ated, no serious cuts, bulges, treadwear or any signs of misalignment;valve stems not touching wheels, rimsor brake drums; valve caps in placeand no objects stuck between thewheels.

Check that both tires are of same type,for example, not mixed radial and biastype and that their circumferences arematched.

Check wheel bearing and hub: no obvi-ous leaking on outside or inside wheel.

Suspension

Check condition of springs (leaf orair), spring hangers, shackles and U-bolts.

Axle alignment.

Brakes

Condition of brake drums. With brakesreleased, look for a noticeable gap be-tween lining and drum (This checkcannot be made if dust covers are inplace).

Condition of brake hoses: check forany chang.

Check brake chamber mounting boltsand brackets.

Check slack adjusters and chamberpush rod travel. With brakes applied orreleased, look for conspicuously dif-ferent positions of the slack adjusters.

Check spring brakes.

Step 6: Rear Of Vehicle Area

Frame Area

Frame or cross members not bent,cracked or otherwise damaged ormissing.

Check that air tubing and electricallines are properly secured to the framewith no damage or chang.

Lights and Reectors Tail lights, brake lights and turn signal

lights: operating, clean and propercolor.


W0001230

Step 7: Coupling System Area

Fifth Wheel

Securely mounted to the frame.

No missing or damaged parts.

Check that trunnion and plate areproperly lubricated ( page 318).

Sliding Fifth Wheel

Mechanism not worn, bent, damagedor parts missing ( page 320).

Properly lubricated.

All locking pins present and locked inplace.

If air operated: no air leaks.

Air Tubing and Electric Lines Visible FromThis Point

Should be secure from dangling.

Both air lines and electric line shouldbe free from damage, oil and grease.

Step 8: Left Saddle Tank and Left RearVehicle Wheels Area






Suspension

Check condition of springs (leaf orair), spring hangers, shackles andU-bolts, no cracks, breaks or shifting.


Brakes

Condition of brake drums. With brakesreleased, look for a noticeable gap be-tween lining and drum (This checkcannot be made if dust covers are inplace).





Condition of Visible Components Transmission: not leaking.

Drive shaft: looks OK.

Exhaust system: secure, not leaking,not touching wires, fuel or air tubing.

Frame and cross members: no bends,cracks or breaks.

Air tubing and electrical wiring: se-cured against snagging and chang.

Left Fuel Tank(s) Securely mounted and not damaged or

leaking.

Fuel lines secure and not leaking.Check that shut-off valves are open.

Tank(s) full of fuel. Cap on and secure.Battery Area

Open the battery box ( page 294). Bat-tery box securely mounted to vehicle.

Batteries secured against movement( page 294).

Battery cases not broken or leaking.Battery cables free from damage.

Tops of batteries and terminals cleanand free from foreign material.

If equipped, replace battery lid andmake sure it is securely fastened( page 295).


W0001230

In the Cab

Check steps and grab handles forlooseness or breakage ( page 23).Also, clean them if there is any sub-stance that makes them slippery, whichmakes cab entry/exit hazardous.

Start the engine. If equipped, checkthat exhaust rain cap opens when ac-celerating engine.

Check gauges and telltale light func-tion ( page 85).

Check function of low air warning( page 91). Check the Graphic Displayfor any fault codes ( page 114).

Check clutch function ( page 269). Ifequipped, check for clutch brake func-tion.

Check windshield wipers and washers( page 47) and horns, including back-up alarm, if equipped.

Clean inside windshield, door win-dows and instruments. Clean mirrors.

Check climate control and defroster( page 174). If equipped, check mirrorheater.

Check condition of warning triangles,re extinguisher and ares ( page 68).

Adjust the seat ( page 195). Checkmirror adjustment.

Check safety belts for function anddamage ( page 55).

Apply service brakes. After initialdrop, pressure should hold steady, orincrease slightly, with engine at idle.

Check steering wheel for excessivefree play.

Check for loose items in the cab. Se-cure them if necessary.


Hooking Up To Trailer

Hook-up Preparation

Check kingpin and mounting plate ontrailer, free from wear, bends or dam-age.

Chock trailer wheels.

Fifth Wheel Or Trailer Hitch No visible space between fth wheel

and trailer ( page 326).

Locking jaws around the shank andnot the head of kingpin ( page 326).

Release lever properly seated andsafety latch/lock engaged ( page 327).

Check all connections to dolly ortrailer hitch and safety chains are se-cured.

Check function of trailer air supplyvalve and trailer brakes.

Sliding Fifth Wheel Check that fth wheel is not so far

forward that the tractor frame willstrike the landing gear during turns.


W0001361

NOTE! Refer to the trailer manufacturersmanual for specic information on thetrailer checks.

Step 9: Trailer Front Area

Air and Electrical Connections

Glad hands properly mounted, freefrom damage and not leaking.

Trailer cord receptacle properlymounted, free of damage; plug prop-erly seated and safety catch engagedto prevent accidental disconnect.

Air and electrical lines properly se-cured against tangling, snagging andchang with sufcient slack for turns.

Step 10: Right Side of Trailer Area

Landing Gear or Dolly Area

Fully raised; no missing or damagedparts.

Crank handle present and secured.

If power operated, no air/hydraulicleaks.

Spare Wheel(s)

Carrier or rack not damaged.

Spare wheel securely mounted in rack.

Tire and wheel condition adequate fora spare: proper size, properly inated.

Lights and Reectors

Trailer side clearance lights: clean, op-erating and proper color.


Frame and Body

Frame and crossmembers not bent,cracked, damaged or missing.

Proper placarding.

Body parts not damaged or missing.


Step 11: Right Rear Trailer Wheel






Suspension

Condition of springs (leaf or air),spring hangers, shackles and U-bolts.

Axle alignment.

Condition of torque rod arms.

If equipped with sliding axles, checkposition and alignment. Look for dam-aged, worn or missing parts, all lockspresent, fully in place and locked.

Flexible air tubing not cracked, cut,crimped or otherwise damaged. Se-cured against tangling, dragging andchang.

Brakes

Condition of brake drums. With brakesreleased, look for a noticeable gap be-

tween lining and drum (This checkcannot be made if dust covers are inplace).





Step 12: Rear of Trailer Area

Lights and Reectors

Rear clearance, identication and taillights clean, operating and propercolor.


Cargo Securement

Cargo properly blocked, braced, tied,chained, etc.

Tailboard up and properly secured.End gates free from damage, properlysecured in stake pockets.

Canvas or tarp (if required) properlylatched down to prevent water damage,tearing, billowing or blockage of eithermirrors or tail lights.

Rear doors securely closed, latched orlocked; required security seals in place.

Underside guard in place: not cracked,bent or broken.


W0001361

NOTE! Refer to the trailer manufacturersmanual for specic information on thetrailer checks.

Step 13: Left Rear Trailer Wheels Area


Check condition of wheels and rims.Especially look for cracks, lockringsmissing, bent or broken spacers, studs,clamps or lugs.




Suspension

Condition of springs (leaf or air),spring hangers, shackles and U-bolts.

Axle alignment.

Condition of torque rod arms.

If equipped with sliding axles, checkposition and alignment. Look for dam-aged, worn or missing parts, all lockspresent, fully in place and locked.

Flexible air tubing not cracked, cut,crimped or otherwise damaged. Itshould be secured against tangling,dragging and chang.

Brakes

Condition of brake drums. With brakesreleased, look for a noticeable gap be-tween lining and drum (This checkcan not be made if dust covers are inplace).






Step 14: Left Side of Trailer Area

Landing Gear or Dolly Area

Fully raised; no missing or damagedparts.

Crank handle present and secured.

If power operated, no air/hydraulicleaks.

Spare Wheel(s)

Spare wheel securely mounted in rackwith no damage to rack.

Tire and wheel condition adequate fora spare: proper size, properly inated.

Lights and Reectors

Trailer side clearance lights: clean, op-erating and proper color.


Frame and Body

Frame and crossmembers not bent,cracked, damaged or missing.

Proper placarding.

Body parts not damaged or missing.

Before Leaving the Parking Area

Remove chocks from the wheels.

Test trailer hook-up by slowly pullingwhile applying the trailer brakes withthe trailer brake hand control valve.

Test the service brakes before leavingthe parking area.

Test parking brakes by stopping on a20% grade and applying the parkingbrakes. The parking brakes shall holdthe combined vehicle and trailer with-out moving.


Daily MaintenanceThe following should be checked daily inaddition to doing the pre-trip inspection ofthe truck or tractor and trailer.

While checking the uid levels, visually in-spect hoses, pipes and their connections forsigns of leakage. Inspect the ground underengine, transmission and rear axle(s) forsigns of leakage.

Before working on or inspecting a vehi-cle, set the parking brakes, place thetransmission in neutral and block thewheels . Failure to do so can result inunexpected vehicle movement and cancause serious personal injury or death.

Check coolant level in the coolant tank.The level should be above the minimummark shown on the side of the tank.

WARNINGDo not remove the cap to the surge tankwhile the engine and radiator are stillhot and under pressure. Scalding uidand/or steam may be blown out underpressure if the cap is taken off too soon.

If the coolant level is low, add morecoolant to the tank so the level is above theminimum mark. Coolant should be lledthrough the cap in the middle of the tank.

CAUTIONTo prevent cooling system damage, addonly pre-mixed coolant made up of 50%clean water and 50% antifreeze. See theOperators Manual, Maintenance &Engine for more detailed information.

W2002049


WARNINGKeep yourself clear of all moving or hotengine parts. A hot engine can cause se-rious burns.

Check oil level in the engine with the dip-stick. The oil level should be between theminimum and maximum marks on the dip-stick.

CAUTIONDo not overll or underll oil. Prema-ture wear or component damage mayresult if you do.

See the Operators Manual, Maintenanceand Engine for correct types of oil used inVolvo engines.

CAUTIONIf the vehicle is equipped with an aero-dynamic bumper, do not step on or pressin between the bumper and the wheel.Breakage or damage may result.

W2002047

To add oil to the engine, remove oil cap onthe valve cover and ll through the hole.

CAUTIONMake sure the oil added is the sametype of oil that is in the engine. Thewrong type of oil could accelerate wearon engine if not suited for application.

W2002048


Check uid level in the clutch uid reser-voir. Fluid level should be between thelevel marks on the reservoir.

If uid needs to be added, use brake uid,DOT 4.

W4000726

Check level in the windshield washer reser-voir. If washer uid needs to be added, usea commercially reputable washer uid thathas good cleaning capability and does notfreeze in cold weather.

Total reservoir capacity is 3.3 gallons(12.5 liters). An indicator will appear onthe diagnostic display when there isapproximately 1.4 gallons (5.3 liters) re-maining in the reservoir. W8000985

Check that windshield wipers and washerare working properly.

The windshield washer spray should coverthe windshield well. The wipers shouldclean the windshield in a couple of strokesand should not leave any streaks.

W3000874


If the windshield needs an overall cleaning,use a long handled cleaning sponge andsqueegee.

Clean the side windows in the same waywith a long handled sponge and squeegee.

W1000070

Check all lights for proper function:

Headlights

Daytime running lights

Parking and marker lights

Stoplights

Turn signals

W3000953

NOTE! Make sure that all uid levels areat their proper levels. If the uids are not attheir proper levels, add as necessary. Referto the Engine and Maintenance Manual forinformation on what types of uids are rec-ommended for your Volvo vehicle.


WARNINGWhen draining the air tanks, do not lookinto the area of the draining air. Dirt orsludge particles may be in the air streamthat could cause eye injury.

Empty out the air tanks daily. With the airsystem fully charged and with the engineshut off, listen for air leaks.

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50 Additional Safety Features

Safety BeltsGeneral

Safety belts must be properly worn at alltimes by the driver and all passengerswhile the vehicle is in motion even ifthe vehicle is equipped with a Supple-mental Restraint System (SRS or airbag). Failure to do so can result in seri-ous personal injury or death in the eventof a sudden stop or collision.

Fasten the safety belt before starting todrive. Trying to fasten the safety beltwhile the vehicle is moving may lead toan accident, causing serious personal in-jury or death.

Safety belt assemblies installed in this vehi-cle meet FMVSS 209, Type 1 and Type2 requirements. They are recommendedfor all persons weighing over 50 lb (25 kg).

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A child restraint system should also be pro-vided for each child weighing 50 lb (25 kg)or less. It should meet the requirements ofFMVSS 213, Child Restraint System.Carefully read and follow all manufac-turers instructions on installation and use.Make certain the child remains in the re-straint system at all times while the vehicleis in motion.

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Additional Safety Features 51

Safety belts must be worn by the driver andall passengers at all times. Before adjustingor fastening the safety belt, move the seatforward or rearward and adjust the seatheight as necessary. Sit erect and adjust theseat cushion and seat back for a comfort-able driving position. In the event of acollision, a correct driving position maxi-mizes the effectiveness of the safety belt.

There are both Federal and State laws gov-erning the use of safety belts. As lawsdiffer from state to state, make yourself fa-miliar with the current rules.

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Tether straps are installed on allsuspension-type seats. Tether straps help se-cure the seat to the oor and are intendedto restrain the seat and safety belt in caseof an accident or sudden stop.

The tethers are not adjustable and do notneed any adjustment.

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Operating the Safety BeltTo fasten the safety belt, pull the belt outfrom the retractor and insert the latch intothe buckle. Verify proper lock of the latchby pulling on the latch.

Adjust the slack by pulling on the top partof the belt until the lower part, or the partthat crosses the lap, is snugly adjusted. Re-lease the top part and let the retractor pullthe belt in.

The lap portion of the safety belt should beworn low across the pelvic region (hipbone) and adjusted snugly. Never adjust thelap belt across the abdomen. A push buttonon the buckle is used to release the safetybelt latch by pushing in the button releaseon the buckle.

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The buckle portion of the safety belt sys-tem is different depending on the seatoption chosen. The National standard andcomfort seat has a separate buckle that isattached to a oor anchor by a seat strap.This seat strap is not adjustable, and doesnot need to be adjusted.The buckle for the seat is bolted to the seatoor.

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If a comfort clip is used on the safety belt,always adjust the latch so that there is amaximum of 1 in. (25 mm) slack betweenthe belt and chest (about the width of twongers). If a larger slack is allowed, the ef-fectiveness of the safety belt is decreased inthe event of a collision. Operation of theclip is described on page 60.

Make sure the safety belt is completely re-tracted and out of the way when not in use.

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Sleeper Safety Restraint

Always use the safety restraint when thevehicle is in motion. Failure to do so notonly may cause severe injuries or deathto the passenger in the event of an acci-dent but also poses a danger of injuriesto other occupants of the vehicle.

Anytime the vehicle is in motion, a pas-senger using the sleeper bunk should bestrapped in using the safety restraint.The top bunk should always be usedwith the harness in place, whether thevehicle is in motion or not. Falling fromthe upper bunk can result in severe per-sonal injury or death.

The restraint netting can be used for secur-ing loose articles. Any loose articles thatcan shift in the cab during hard corneringor braking should be kept restrained.

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Fasten the restraint by connecting thebuckle with the latch. Make sure the beltsare not twisted. Test the latch connectionby pulling on the belt. If they come apart,reconnect and test again. If the connectioncan not be made, replace the belt before us-ing the bunk for sleeping during driving.

To loosen the restraint, press the red releasebutton on the latch (1). Restraints should beproperly stored when not used. Having therestraint laying loose in the cab can be asource for unintentional snagging.

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Safety Restraint VN-420, VN610 and VN660The restraint has latches in one end andbuckles in the other so it can only be in-stalled one way. Connect the restraint to theback wall and the buckles on the oor. Con-nect the side tethers and adjust the straps toform a tent over the bunk (VN-660 upperbunk does not have the tenting feature).

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Safety Restraint VN-770Connect the restraint to the back wall rst.The wall connectors are located in the stor-age units. Connect the lower part of therestraint to the lower buckles. Connect theside tethers and adjust the straps to form atent over the bunk.

NOTE! The restraints for top and bottombunks are different. Each belt can only beinstalled to the correct bunk.


Inspection

Failure to properly inspect and maintainthe safety belts can cause serious per-sonal injury or death.

It is critical that any time a vehicle hasbeen involved in an accident, the entiresafety belt system must be replaced inthe vehicle (which also includes thesleeper bunk restraints) if they were inuse at the time of the accident. Failureto replace the safety belt system may re-sult in serious injury or death.

A damaged safety belt, whether visiblydamaged or not, could result in seriouspersonal injury in the event of an acci-dent. The safety belt systems should bereplaced at least every ve years.

Do not bleach or re-dye the color web-bing because it may cause a severe lossof belt strength. This loss of strengthcould allow the safety belt to breakunder stress, thus resulting in severe per-sonal injury or death.

Check the belts, buckles, latch plates, re-tractors, anchorages, and guide loops toensure that they are working properly. Lookfor loose/damaged parts (without disassem-bling) that could keep the restraint systemfrom working properly. If the safety belt,retractor and hardware were in use during acollision, they must be replaced. The re-straint system anchorage fasteners must bereplaced if necessary. If there is any doubtabout the restraint systems effectiveness,replace the entire safety belt assembly.


The following maintenance guidelines de-tail how to inspect safety belts and tethersfor cuts, fraying, extreme or unusual wearof the webbing, etc., and damage to thebuckle, retractor, hardware or other factorswhich indicate that safety belt system re-placement is necessary.

Check the web wear at the buckle/latcharea. The webbing must be closely exam-ined to determine if there are any cuts,fraying or extreme wear in the webbing.Cuts, fraying or excessive wear would indi-cate the need for replacement of the safetybelt system.

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The D-loop web guide is an area where al-most constant movement of the safety beltwebbing occurs because of the relativemovement between the seat and the cab.This constant movement forms an areawhere wear will often occur. The webbingmust be closely examined to determine ifthere are any cuts, fraying or extreme wearin the webbing. Cuts, fraying or excessivewear would indicate the need for replace-ment of the safety belt system.

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Check to make sure that the D-loop webguide is rotating properly. If the guide isnot rotating properly, the webbing will pullat the wrong angle through the guide, ac-celerating wear.

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If equipped, check the comfort clip forcracks or possible damage. Make sure thatit works properly.

Check the buckle by inserting the latch andverifying proper operation. Determine if thelatch plate is worn or deformed. Check thebuckle and latch casing for cracks orbreakage.

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The retractor web storage device ismounted on the B-pillar, just behind thedoor in the cab. The retractor is the heart ofthe safety belt system and can be damagedif abused, even unintentionally. Check theretractor web storage device operation toensure that it is not locked and that it spoolsout and retracts the webbing properly.

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If tethers are being used to anchor thesafety belts to the oor, make sure that theyare properly attached to the seat. Tethersmust also be inspected for web wear andproper tightness of mounting hardware.

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All hardware for safety belt mountingpoints should be evaluated for corrosion.All attachment points of the system shouldbe checked for tightness of mountinghardware.

Check the web in areas exposed to ultra-violet rays from the sun or extreme dust ordirt. If the original color of the web inthese areas is extremely faded, the physicalstrength of this web may have deteriorated.If this condition exists, replace the safetybelt system.


Important Facts About Safety Belts in Heavy TrucksThe high mileage associated with heavytrucks, the continual relative movement ofthe seat with the cab, the possible contactwith the vehicle seat or other parts of thecab structure, and the potential exposure ofthis safety belt to severe environmental con-ditions make it crucial to inspect the seatbelt system regularly. It is recommendedthat the system be inspected every 15,000miles (24,000 km) or more often if the ve-hicle is exposed to severe environmental orvocational conditions. Any safety belt sys-tem that shows cuts, fraying, extreme orunusual wear, signicant discolorations dueto ultra-violet ray exposure, dusty-dirtyconditions, abrasion to the safety belt web-bing or damage to the buckle, latch plate,retractor, hardware or any other obviousproblem should be replaced immediately,regardless of the mileage.

Once replacement of the safety belt hasbeen determined necessary, be certain thatit is replaced only with a Volvo original re-placement safety belt. See your authorizedVolvo Truck dealer for replacement. YourVolvo safety belt system has been devel-oped and tested specically for heavytrucks. Replace it only with the exact samedesign that the vehicle was equipped with.

If the inspection indicates that any otherpart of the safety belt system requires re-placement, the entire belt system must bereplaced. An installation guide is attachedto every replacement system, entitledThree-Point Safety Belt InstallationGuide. There are separate safety beltinstruction guides for suspension and sta-tionary seats. Use the proper guide for yourtype of seat and follow the instructionsvery closely. It is vitally important that allcomponents are mounted back in the samepositions as the original components thatwere removed. This will maintain the de-sign integrity of the mounting points for thesafety belt assembly.


Comfort Clip OperationWhen provided, the comfort clip is locatedon the shoulder strap just below the D-ring.When adjusting the comfort clip, the fol-lowing procedure must be followed forproper adjustment:1 Pull out only enough webbing to allow

slight pressure to the shoulder andchest. Allow no more than a 1 in.(25 mm) slack when measured be-tween the chest and the belt.

2 To activate the clip mechanism feature,lift the lever up to clamp the webbingin place.

NOTE! When the safety belt is not in use,the clip should be in the open position toallow the seat belt to retract to its properposition. Also make sure that the adjust-ment of the comfort clip does not interferewith the operation of the safety belt.

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Open position

Always adjust the clip so that there is amaximum of 1 in. (25 mm) of slack be-tween the belt and chest (about two ngerswidth). If a larger slack is allowed, the ef-fectiveness of the safety belt is decreased inthe event of a collision.

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SRS Airbag

WARNINGThe SRS airbag is intended to supple-ment not replace the standardsafety belt. The airbag is not deployedwhen the truck is hit from behind, fromthe side or if it rolls over. For best pro-tection, sit in a normal, upright position.Always wear the safety belt.

For added safety, the vehicle may beequipped with an airbag or SRS (Supple-mental Restraint System) as a supplementto the standard three-point anchored safetybelt. The SRS is designed to reduce the riskof injury to the drivers face and upper partof the body. Together with the safety belt,the airbag helps prevent the driver from be-ing thrown against the steering wheel,windshield or other hard surfaces in the cab.

The Volvo SRS Airbag provides increasedprotection in frontal collisions, where thevehicle collides with a xed or heavy objectwith enough force to activate the sen

volvo operator s manual vnl and vnm 2001

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