PV776-20 003739

This booklet replaces “Quick-Reference Guide VN, VHD VERSION2” dated January 2003, Publication No. PV776-20 182094

Quick-Reference Quick-Referen ce Guide VN, VHD VERSION2 December 2004 2004

Foreword This book is intended primarily for technicians, but also may be helpful to others who need technical information about the vehicle or related components. Information has been compressed to accommodate the size restrictions of this format. Therefore, always refer to the appropriate technical service information for the most complete and current data.

The following levels of observations, cautions and warnings are used in this Service Documentation: Danger: Indicates an unsafe practice where serious personal injury or death could occur. Warning: Indicates an unsafe practice where personal injury or severe damage to the product could occur. Caution: Indicates an unsafe practice where damage to the product could occur. Note: Indicates a procedure, practice, or condition that must be followed in order to have the vehicle or component function in the manner intended.

Volvo Trucks North America, Inc. Greensboro, NC USA

Order number: PV776-20 003739 © 2004 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 0. General ............................................... 1

5. Brakes ............................................... 80

Tightening Torques, General ................. 1 Data Link Communication .................... 3

Specifications ......................................... 80 Drum Brake ......................................... 80

Vehicle Identification ........................... 14

Compressor .......................................... 82 Air Drier .............................................. 86 Brake Valves ........................................ 89

1. Service and Maintenance ................ 16

Oil Change Volumes .............................. 16 2. Engine ............................................... 19

6. Suspension and Steering ................. 97

Specifications ......................................... 19

Specifications ......................................... 97

General ................................................ 19 Engine .................................................. 21 Valves .................................................. 23

Wheel Alignment ................................ 97 Steering ................................................ 98

Timing Gears and Camshaft ................ 28

7. Chassis, Springs, Damping, and Wheels ................................................. 101

Lubrication and Oil Systems ............... 37 Fuel System ......................................... 39

Specifications ....................................... 101 Suspension ......................................... 101

Intake and Exhaust System .................. Cooling System ................................... Engine Control System ........................ Tightening Torques and Patterns ......... 3. Electrical System and Instruments

40 47 50 55 74

Specifications ......................................... 74 Fuse and Relay Locations .................... 74 Tightening Torques .............................. 75 Group 35 — Light Control Module .... 77

Wheels ............................................... 106 8. Body, Cab, and Interior Trim ....... 108

Specifications ....................................... 108 Cab Designations ............................... 108 Seats ................................................... 109 Climate Control Unit ......................... 110

0. General Tightening Torques, General Strength Classes 4.8, 5.8 4.8

5.8

Thread

Nm (ft-lb)

Thread

Nm (ft-lb)

M3

0.6 ± 0.1 (0.4)

M5

3.5 ± 0.5 (2.5)

M4

1.5 ± 0.5 (1.1)

M6

6 ± 1 (4.4 ± 0.7)

M5

3 ± 0.5 (2.2)

M8

15 ± 2.5 (11 ± 1.8)

M6

5 ± 0.8 (3.6)

M10

30 ± 4.5 (22 ± 3.3)

M8

12 ± 2 (8.8 ± 1.4)

M12

50 ± 8 (37 ± 6)

M10

24 ± 4 (18 ± 3)

Strength Classes 8.8, 10.9 Level

Application

Action after choice

Low

Joints with low friction (μ

None

≈ 0.1) Average

General application (μ ≈ 0.15)

None

High

Joints with high friction (μ

Test

≈ 0.2) E.g. weld nuts of height 1

1d. , untreated steel surfaces, mm 1

d = thread diameter Thread

Strength class 8.8, Nm (ft-lb) Low

Average

High

M5

5 ± 0.8 (3.7)

6 ± 1 (4.4 ± 0.7)

7 ± 1.2 (5.2 ± 1)

M6

8 ± 1.2 (6 ± 1)

10 ± 1.5 (7 ± 1)

12 ± 2 (9 ± 1.4)

M7

15 ± 2.5 (11 ± 1.8)

17 ± 3 (13 ± 2)

20 ± 3 (15 ± 2)

M8

20 ± 3 (15 ± 2)

24 ± 4 (18 ± 3)

28 ± 5 (21 ± 3)

M10

40 ± 6 (30 ± 4)

48 ± 8 (35 ± 6)

56 ± 10 (41 ± 7)

M12

70 ± 12 (52 ± 9)

85 ± 15 (63 ± 11)

100 ± 15 (74 ± 11)

M14

115 ± 20 (85 ± 15)

140 ± 25 (103 ± 18)

160 ± 25 (118 ± 18)

M16

185 ± 30 (137 ± 22)

220 ± 35 (162 ± 26)

255 ± 40 (188 ± 30)

M18

250 ± 40 (185 ± 30)

290 ± 45 (214 ± 33)

340 ± 50 (251 ± 37)

1

2

0. General

Thread


Average

High

M20

360 ± 55 (266 ± 41)

430 ± 70 (317 ± 52)

500 ± 80 (369 ± 59)

M22

490 ± 80 (362 ± 59)

580 ± 90 (428 ± 66)

680 ± 100 (502 ± 74)

M24

620 ± 100 (458 ± 74)

740 ± 120 (546 ± 89)

860 ± 140 (635 ± 103)

Thread


Average

High

M5

6 ± 0.1 (4.4)

7.5 ± 1.2 (5.5 ± 1)

9 ± 1.5 (6.6 ± 1)

M6

10 ± 1.5 (7.3 ± 1)

12 ± 2 (9 ± 1.4)

15 ± 2.5 (11 ± 2)

M7

15 ± 2.5 (11 ± 2)

22 ± 3 (16 ± 2)

24 ± 4 (18 ± 3)

M8

25 ± 4 (18 ± 3)

30 ± 5 (22 ± 3.7)

35 ± 6 (26 ± 4)

M10

50 ± 8 (37 ± 6)

60 ± 10 (44 ± 7)

70 ± 12 (52 ± 9)

M12

85 ± 15 (63 ± 11)

105 ± 20 (77 ± 15)

125 ± 20 (92 ± 15)

M14

150 ± 25 (111 ± 18)

175 ± 30 (129 ± 22)

200 ± 30 (148 ± 22)

M16

230 ± 35 (170 ± 26)

275 ± 45 (203 ± 33)

320 ± 50 (236 ± 37)

M18

310 ± 50 (229 ± 37)

360 ± 55 (266 ± 41)

410 ± 60 (303 ± 44)

M20

450 ± 70 (332 ± 52)

540 ± 90 (399 ± 66)

630 ± 100 (465 ± 74)

M22

610 ± 100 (450 ± 74)

730 ± 120 (539 ± 89)

850 ± 140 (627 ± 103)

M24

750 ± 120 (554 ± 89)

900 ± 140 (664 ± 103)

1050 ± 160 (775 ± 118)

0. General Data Link Communication Communication between the different Electronic Control Units (ECUs) takes place via the two data links: the J1939 control data link and the J1587/1708 information data link. The diagram below shows how the control units, the diagnostic connector, and the instrument cluster are connected in principle. The instrument cluster, the Engine ECU (EECU), vehicle ECU (VECU), Light Control Module (LCM) and the diagnostic connector are always included in the system. The system may include other control units, depending on the vehicle type and optional equipment.

W3005654

3

4

0. General

Fault Codes MID

Message Identification Description (identification of ECU)

PID

Parameter Identification Description (identification of parameter (value))

PPID Proprietary Parameter Identification Description (Volvo-unique identification of parameter (value)) SID

Subsystem Identification Description (identification of component)

PSID Proprietary Subsystem Identification Description (Volvo-unique identification of component) FMI

Failure Mode Identifier (identification of fault type)

0. General

5

MIDs MID 128 MID 130 MID 136 MID 140 MID 142 MID 144 MID 146 MID 216 MID 232 MID 249

Engine Electronic Control Unit (EECU) Transmission ECU Anti-lock Brake (ABS) control unit Instrument cluster Satellite Communications Vehicle control unit (VECU) Climate control unit Lighting control module (LCM) Airbag (SRS), control unit Bodybuilder module (BBM)

MID 250 J1939–1 J1939–2

J1939–3

J1939–4

Steering wheel module (SWM) Main network SAE J1939 Section of SAE J1939 connected to the vehicle control unit Section of SAE J1939 connected to the instrument cluster Section of SAE J1939 connected to the bodybuilder control unit

6

0. General

Common Fault Codes MID 128 Fault code diagnostics, refer to MID 128 fault codes, IMPACT or ID DVD: Info type “Diagnostics” group 2841 Fault Code PID 26 PID 27

Component/Function

PID 84

Vehicle speed

PID 85

Cruise control status

PID 91

Accelerator pedal position

PID 94

Fuel supply pressure

PID 97

Water in fuel indicator

PID 105

Intake manifold temperature

PID 108

Atmospheric pressure

PID 110

Engine coolant temperature

PID 158

PPID 119

High coolant temperature

PPID 122

VCB compression brake status

PPID 124

EPG 1

SID 1-6

1/2/3/4/5/6 Unit injectors

SID 18

Drain Valve, Water Separator

SID 21

Engine position, cam sensor

SID 22

Engine speed, flywheel sensor

SID 33

Fan control

SID 70

Preheater element 1

SID 71

Preheater element 2

SID 78

Fuel supply pump

SID 146

EGR valve 1

SID 211

5 volt DC supply

SID 230

Idle validation switch

SID 231

SAE J1939 Control link

SID 232

5 Volt DC supply

SID 240

Program memory

SID 253

Data set memory EEPROM

SID 254

Engine ECU (EMS2)

SID 266

EGR valve 2

SID 281

EGR reed valve diagnose

SID 282

EGR cooler efficiency

PSID 201

SAE J1939 Data link interuption

Engine oil pressure Intake manifold pressure

PID 153

Engine brake torque percent

Engine oil level

PID 102

PID 111

PPID 86

EGR position sensor 1 Preheater status

PID 100

Component/Function

Fan speed %

PID 45

PID 98

Fault Code

Engine coolant level Crankcase pressure Battery voltage

PID 171

Ambient temperature

PID 172

Air temperature, intake

PID 175

Engine oil temperature

PID 228

Road speed sensor calibration

PID 245

Total Vehicle Distance

PID 362

EGR position sensor 2

0. General

7

MID 136 Fault Code

Component/Function

Fault Code

Component/Function

SID 1

ABS sensor, axle 1 L

SID 10

ABS valve, axle 2 R

SID 2

ABS sensor, axle 1 R

SID 11

ABS valve, axle 3 L

SID 3


SID 12

ABS valve, axle 3 R

SID 4


SID 13

ABS retarder control relay

SID 5


SID 14

ABS relay, diagonal 1

SID 6


SID 15

ABS relay, diagonal 2

SID 7

ABS valve, axle 1 L

SID 18

ABS, ASR valve, diff 1

SID 8

ABS valve, axle 1 R

SID 19

ABS, ASR valve, diff 2

SID 9

ABS valve, axle 2 L

MID 140 Fault code

Component / function

Fault code


PID 77

Forward rear axle temperature

SID 240

Program memory

PID 78

Rear rear axle temperature

SID 250

SAE J1587/J1708 data link

PID 96

Fuel level

SID 253

Calibration memory, EEPROM

PID 116

Application air pressure

PSID 7

Internal reference resistance

PID 117

Air brake pressure, front

PSID 200

Open-circuit, J1939 Data Link, EECU

PID 118

Air brake pressure, rear

PSID 201

Open-circuit, J1939 Data Link, VECU

PID 158

Battery voltage

PSID 204

Open-circuit, J1939 Data Link, ABS

PID 171

Ambient temperature

PID 177

Transmission oil temperature

PID 178

Air suspension pressure, front

PID 179

Air suspension pressure, rear

SID 231

SAE J1939 Data Link

unit PSID 210

Open-circuit J1939 Data Link, Lighting control module

PSID 232

SAE J1939-3 Data Link

8

0. General

MID 142 Fault Code

Component/Function

Fault Code

Component/Function

PID 155

Output 1-4

PSID 4

GPS module/interface

PID 155

Input 1-4

PSID 5

DSP module/interface

PID 154

Input 5-8

PSID 6

ORBCOMM satellite module/interface

SID 240

Memory flash/RAM

PSID 8

J1708/1587 road speed

SID 250

J1708/1587 Data Link

PSID 161

J1708/1587 VIN missing

SID 253

Memory ROM

PSID 162

VIN mismatch

PSID 3

Sending message failure

MID 144 Fault code

Component

Fault code

Component

PID 84

Vehicle speed

SID 231

SAE J1939 Control Data Link

PID 91

Accelerator pedal, percentage position

SID 240

Program memory

PID 150

PTO output (Volvo engine only)

SID 243

Cruise control, set switch

PID 152

VECU, number of resets

SID 250

Information link SAE J1708

PID 191

Output shaft speed

SID 253

Calibration memory EEPROM

PPID 61

Retarder switches (Volvo engine only)

PSID 4

Engine brake stalk lever (Cummins

PPID 69

Buffered idle validation switch (Volvo

6–level engine brake only)

engine only)

PSID 200

Engine timeout

PPID 70

Pedal switches, supply

PSID 202

Instrument timeout

PPID 71

Cruise control and engine brake, switch

PSID 204

ABS/EBS timeout

PSID 210

LCM timeout

PSID 214

BBM timeout (VOLVO engine only,

supply PPID 72

Accelerator pedal and engine brake, sensors supply

PPID 74

VECU power supply

SID 230

Idle validation switch 1

vehicles equipped with BBM)

0. General

9

MID 146 Fault code


Fault code


PID 170

Cab, temperature sensor

SID 14

Circulation fan, temperature sensor, cab

PID 171

Temperature sensor, outer temperature

SID 15

Fan connection, engine

SID 2

Temperature sensor, evaporator

SID 16

Stepper motor, phase 1

SID 5

Stepper Motor, Fresh Air and

SID 17


SID 18


SID 19


SID 22

Pressure sensor, refrigerant, high

Recirculation SID 6

Stepper motor, air distribution

SID 9

Stepper motor, air mixture Electronic Climate Control (ECC), heat control

pressure side

Manual Climate Control, (MCC, BAS) SID 232

5 volt supply to the sensor

compressor

SID 250

SAE J1708 data link

SID 12

Solenoid valve, water control

PID 170

Cab, temperature sensor

SID 13

Temperature sensor, heat exchanger

SID 11

Magnetic clutch, air conditioning (A/C)

10

0. General

MID 216 Fault code


Fault code


SID 240

Program memory

PSID 34

Power supply 1

SID 250

SAE J1587/1708 Information link

PSID 35

Power supply 2

SID 253


PSID 36

Power supply 3

SID 254

Control unit

PSID 37

Power supply 4

PSID 1

High beam, left

PSID 38

Power supply 5

PSID 2

Low beam, left

PSID 39

Power supply 6

PSID 3

High beam, right

PSID 40

Power supply, ignition key in driving

PSID 4

Low beam, right

PSID 5

Fog lights

PSID 7

Driving lights

PSID 8

Reverse lights

PSID 10

Brake light, left

PSID 11

Brake light, right

PSID 12

Brake lights, trailer

PSID 13

Direction indicator, left front

PSID 14

Direction indicator, right front

PSID 17

Direction indicator trailer, left side

PSID 18

Direction indicator trailer, right side

PSID 19

Relay, intermittent wiper

PSID 20

Dashboard dimming

PSID 27

Snow plow lights

PSID 28

Hazard sound indication

PSID 29

Indicator light, warning light

PSID 30

Light switch, warning light

PSID 33

Stalk switch high/low beam

position PSID 41

Stalk switch direction indicator

PSID 42

Rheostat, instrument lighting

PSID 45

Side repeater, right

PSID 46

Side repeater, left

PSID 48

Park and licence plate lights, tractor rear

PSID 49

Tractor roof marker/clearance lamps

PSID 50

Tractor front park lights

PSID 51

Trailer park lights

PSID 52

Allison retarder indicator LED

PSID 53

Marker (ICC) trailer

PSID 54

Marker interrupt

PSID 55

Headlamp interrupt

PSID 57

Back of cab lights

PSID 200

SAE J1939 Open-circuit, data link, engine control unit

PSID 201

SAE J1939 Open-circuit, data link, vehicle control unit

0. General

11

MID 232 Fault Code

Component/Function

Fault Code

Component/Function

SID 1

Detonation circuit, airbag module

SID 254

Defective unit or component

SID 240

Program memory

PSID 1

Wrong VIN response

SID 253

Calibration memory

PSID 2

No VIN response

Fault Code

Component/Function

Fault Code

Component/Function

PID 29

Extra throttle control, percentage

PSID 201

SAE J1939 open circuit, Data Link,

MID 249

position SID 230

Idle switch

SID 231


SID 253


PSID 200

SAE J1939 open circuit, Data Link,

vehicle ECU PSID 202

SAE J1939 open circuit, Data Link, instrument cluster ECU

PSID 205

SAE J1939 open circuit, Data Link, automatic transmission ECU

engine ECU

MID 250 Fault Code

Component/Function

Fault Code

Component/Function

SID 231


PSID 6

Volume (-)

SID 251

Power supply, control unit steering

PSID 9

Headlamp interrupt

PSID 10

Marker interrupt

PSID 17

Power supply, switch steering wheel

functions (SWM) SID 254

Control unit steering wheel module (SWM)

PSID 3

Arrow left

PSID 4

Arrow right

PSID 5

Volume (+)

buttons PSID 18

Data link, switch steering wheel buttons

12

0. General

FMI Table FMI

Display Text

SAE Standard Text

0

“Value too high”

Correct value, but above normal working range

1

“Value too low”

Correct value, but below normal working range

2

“Faulty data”

Intermittent or faulty data.

3

“Electrical fault”

Abnormally high voltage or short circuit to higher voltage

4


Abnormally low voltage or short circuit to lower voltage

5


Abnormally low current or open circuit

6


Abnormally high current or short circuit to earth (ground)

7

“Mechanical faults”

Faulty response from mechanical system.

8

“Mechanical or electrical fault”

Abnormal frequency

9

“Communication fault”

Abnormal updating rate

10

“Mechanical or electrical fault”

Abnormally large variations.

11

“Unknown fault”

Unidentifiable fault

12

“Component fault”

Faulty unit or component, or loss of communication

13

“Faulty calibration”

Calibration values outside limits

14

“Unknown fault”

Special instructions.

15

“Unknown fault”

Reserved for future use.

0. General

13

Diagnostic Connector

W3005648

Fig. 1: Diagnostic Connector

9–pin Diagnostic Connector Cavity Position

Circuit Description

A

0Z (B-)

B

402 (B+)

C

406C (CAN_H, yellow)

D

407C (CAN_L, green)

E

not used

F

400G (SAE A, 1708)

G

401G (SAE B, 1708)

H

not used

J

196DR (Ignition)

The diagnostic connector is a round connector located in the driver’s side kick panel. The diagnostic connector connects to both the J1939 and J1587/1708 data link and gives the system a way to communicate with an external PC or diagnostic tool. With a PC or diagnostic tool connected, fault codes can be read from all the control units. This is important in fault tracing to carry out basic checks of all the vital parts of the vehicle’s electronics. Most programming can also be done via the diagnostic connector.

14

0. General

Vehicle Identification Labels It is extremely important that the correct vehicle model and Vehicle Identification Number (VIN) 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.

Vehicle Identification Label

The full 17-digit VIN is shown on the Vehicle Identification label located in the door opening on the driver’s side. The VIN contains the following information:

• • • • • • • •

Manufacturing location Engine type Check sum figure Assembly factory Type of cab Brakes / axle combination Model year Chassis number

Certification Label W8003115

Three labels are located in the rear inside frame of the driver side door frame. These labels should not be removed. On the top part of the door frame is the Certification label showing the axle and load ratings for the vehicle as it is built. DO NOT exceed these ratings by overloading.

Noise Emission Control Label The Noise Emission Control label is located at the bottom of the three labels on the rear inside frame of the driver side door. It is the Owner’s responsibility to maintain the vehicle so that it conforms to EPA regulations.

0. General

15

Chassis Number The 8-digit chassis number is embossed into the frame rail at two locations: the bottom flange right-hand side, and the top flange left-hand side of the frame rail. These numbers are set 1065 mm (42 in.) back from the front edge of the frame rail.

W0001995

Engine The Volvo D12D engine serial number is located on the rear, left side of the cylinder block. The serial number can also be found on the certification label on the valve cover.

W2003921

Rear Axle The axle model and serial number is located on the front left side of the forward drive axle and the front right side of the rear drive axle. It is also located on the front right side of the single axle.

W4002560

Transmission

The transmission label may include the type of transmission, part number, serial number, and service category. Location of the label depends on transmission manufacturer.

16

1. Service and Maintenance

Oil Change Volumes

For the most current information on oil capacities and oil change intervals, refer to Service Bulletin 175-60, “Oil and Filter Change Intervals for VOLVO Components.”

For the most current list of approved oils for specific applications, refer to Service Bulletin 175-61, “Approved Oils List, VOLVO Components.”

Engine Approximate oil change capacity Vehicle

VN VHD

Normal oil change (incl. filter)

Dry capacity

Max. to Min. on dipstick

D12D

33 L (35 qts)

37 L (39 qts)

8L (8.5 qts)

D12D

38 L (40 qts)

42 L (44 qts)

6L (6.5 qts)

Engine

Power Take-off Model

Oil change volume, approx.

flywheel-mounted

5.0 L (5.3 qt)


17

Rear Axle Model

Approx. oil change volume, L (qt) Final drive

Total

RSS1344B

17.5 L (18.5 qt)

17.5 L (18.5 qt)

RS1356SV Leaf springs

8.5 L (9 qt)

8.5 L (9 qt)

RS1356SV Air springs

9 L (9.5 qt)

9 L (9.5 qt)

1

19 L (20.1 qt)

1.5 L (1.6 qt)

22 L (23.2 qt)

RS1352HV Leaf springs

20 L (21.1 qt)

3 L (3.2 qt)

26 L (27.5 qt)

RS1352HV Air springs

16 L (16.9 qt)

3 L (3.2 qt)

22 L (23.2 qt)

RS1365HV

22 L (23.2 qt)

3 L (3.2 qt)

28 L (29.6 qt)

19 L (20.1 qt)

1.5 L (1.6 qt)

22 L (23.2 qt)

RS1370HV Leaf springs

20 L (21.1 qt)

3 L (3.2 qt)

26 L (27.5 qt)

RS1370HV Air springs

16 L (16.9 qt)

3 L (3.2 qt)

22 L (23.2 qt)

CTEV87 (front axle) Leaf springs

20 L (21.1 qt)

20 L (21.1 qt)

CTEV87 (rear axle) Leaf springs

9 L (9.5 qt)

9 L (9.5 qt)

CTEV87 (front axle) Air springs

16 L (16.9 qt)

16 L (16.9 qt)

CTEV87 (rear axle) Air springs

7.5 L (7.9 qt)

7.5 L (7.9 qt)

RT2610HV (front axle) Leaf springs

23 L (24.3 qt)

3 L (3.2 qt)

30 L (31.2 qt)

RT2610HV (rear axle) Leaf springs

19 L (20.1 qt)

3 L (3.2 qt)

26 L (27.5 qt)

RT2610HV (front axle) Air springs

23 L (24.3 qt)

3 L (3.2 qt)

29 L (30.6 qt)

RT2610HV (rear axle) Air springs

19 L (20.1 qt)

3 L (3.2 qt)

25 L (26.4 qt)

22.5 L (23.8 qt)

1.5 L (1.6 qt)

25.5 L (26.9 qt)

22.5 L (23.8 qt)

3 L (3.2 qt)

28 L (29.6 qt)

18.5 L (19.5 qt)

1.5 L (1.6 qt)

21.5 L (22.7 qt)

RT3210HV(rear axle) Leaf springs

18.5 L (19.5 qt)

3 L (3.2 qt)

24 L (25.3 qt)

RTH2610B (front axle) Leaf springs

23 L (24.3 qt)

3 L (3.2 qt)

30 L (31.7 qt)

RTH2610B (rear axle) Leaf springs

19 L (20.1 qt)

3 L (3.2 qt)

26 L (27.5 qt)

RS1352HV

RS1370HV

1

RT3210HV (front axle)

1

RT3210HV (front axle) Leaf springs RT3210HV (rear axle)

1

Each hub

1

The oil volume is only 1.5 liter for hub reduction housings with part numbers 1524851 or 1524852. These markings can be seen on the hub reduction housings.

18


Driving Front Axle Model


FS0910HZ

11.5 L (12.1 qt) Please note that the hub change volumes are not included in these figures. The change volume for each hub is 1.5 liter (1.6 qt).

Transfer Case Model


VT2501TB

5.5 L (5.8 qt)

Hydraulic Retarder Model

RET-TH


5.4 ± 0.1 L (5.7 ± 0.1 qt)

2. Engine

19

Specifications General

1

Power Output 1

Torque 2

D12D 365

272 kW (365 hp)

1800 Nm (1328 ft-lb)

D12D 395

295 kW (395 hp)

2000 Nm (1476 ft-lb)

D12D 425

317 kW (425 hp)

2000 Nm (1476 ft-lb)

D12D 435

325 kW (435 hp)

2100 Nm (1549 ft-lb)

D12D 465

347 kW (465 hp)

2237 Nm (1650 ft-lb)

Max power output at 30.0 rps (1800 rpm). Net power according to ISO 1585. Smoke requirements met according to ECE reg 24 Federal Register and Swedish Authorities.

2

Max torque at 20.0 rps (1200 rpm). Net torque according to ISO 1585. Smoke requirements met according to ECE reg 24 Federal Register and Swedish Authorities.

20

2. Engine

General Engine Specifications Number of cylinders

6

Cylinder diameter

131 mm (5.16 in.)

Stroke

150 mm (5.91 in.)

Displacement

12.1 L (738.39 cubic in)

Firing sequence

1-5-3-6-2-4

Compression ratio

17.3:1

Compression test using VCADS Pro, deviation from peak value 100%

max 20%

Engine speed during compression test, minimum

16.7 r/s (100 rpm)

Low idle

8.3 - 10.8 r/s (550 650 rpm)

High idle

38.4 r/s (2300 rpm)

Max. full load revs

35.0 r/s (2100 rpm)

Weight, engine with flywheel, flywheel casing and turbocharger, without starter motor (dry)

1175 kg (2585 lb)

Max length

1350 mm (53.2 in.)

Max width

768 mm (30.2 in.)

Max height

1152 mm (45.4 in.)

2. Engine

21

Engine Cylinder Cylinder Head Type

6 cylinder

Length

1078 mm (42.4 in.)

Width

397 mm (15.6 in.)

Height

135 mm (5.3 in.)

Maximum unevenness (bottom face)

0.1 mm (0.004 in.)

Cylinder Head Bolts Number/cylinder head

38

Thread size

M16

Length

200 mm (7.87 in.)

Cylinder Block Length

1052 mm (41.42 in.)

Height, lower block face - crankshaft center

120 mm (4.72 in.)

Cylinder Liner Type

Wet, replaceable

Height, total

273 mm (10.75 in.)

Sealing surface height above block face

0.15 - 0.21 mm (0.006 - 0.008 in.)

Number of sealing rings per cylinder liner

1+3

22

2. Engine

Piston Type

steel

Height above cylinder block face

0.15 - 0.65 mm (0.006 - 0.026 in.)

Diameter, combustion chamber

89 mm (3.50 in.)

Depth, combustion chamber

18.6 mm (0.73 in.)

Number of ring grooves

3

Front marking

arrow turned forward

Wrist pin diameter

55 mm (2.17 in.)

Piston Rings Compression rings

Specification

Wear tolerance

Number

2

-

0.09 - 0.13 mm (0.0035 0.0051 in.)

-

Piston ring clearance in grooves: lower compression ring

Piston ring gap measured in ring opening: upper compression ring

0.4 - 0.65 mm (0.016 0.026 in.)

< 1.0 mm (0.039 in.)

lower compression ring

1.1 - 1.3 mm (0.043 0.051 in.)

< 1.6 mm\ (0.063 in.)

Oil scraper ring

Specification

Wear tolerance

Number

1

-

Width, including spring

4.32 mm (0.170 in.)

-

Piston ring clearance in groove

0.05 - 0.10 mm (0.0019 - 0.0039 in.)

-

Piston ring gap measured in ring opening

0.35 - 0.65 mm (0.0137 - 0.0260 in.)

< 1.0 mm (0.039 in.)

2. Engine

23

Valves Valve disc, diameter:

Intake

40 mm (1.6 in.)

Exhaust

40 mm (1.6 in.)

Valve stem, diameter:

Intake

8 mm (0.315 in.)

Exhaust

8 mm (0.315 in.)

Valve seat angle (A):

Intake

29.5

Exhaust

44.5

Seat angle in cylinder head (B):

Intake

30

Exhaust

45 T2019432

Clearance between valve head and cylinder head face: Specification

Wear tolerance

Intake

0.9 - 1.4 mm (0.035 - 0.055 in.)

< 1.5 mm (0.059 in.)

Exhaust

1.2 - 1.7 mm (0.047 - 0.067 in.)

< 1.8 mm (0.071 in.)

Note: Valves must be replaced when replacing valve seats.

24

2. Engine

Valve clearance, cold engine, setting value: Intake

0.2 mm (0.008 in.)

Exhaust

0.5 mm (0.019 in.)

Exhaust, VEB

1.6 mm (0.063 in.)

Valve clearance, cold engine, control values: Intake

0.15 - 0.25 mm

(0.006 - 0.009 in.)

Exhaust

0.45 - 0.55 mm

(0.018 - 0.022 in.)

Exhaust, VEB

1.55 - 1.65 mm

(0.061 - 0.065 in.)

Valve Seats Outer diameter (A) Standard:

Intake

43.1 mm (1.697 in.)

Exhaust

43.1 mm (1.697 in.)

Oversize:

Intake

43.3 mm (1.705 in.)

Exhaust

43.3 mm (1.705 in.)

Height (B):

Intake

7.3 mm (0.287 in.)

Exhaust

8.0 mm (0.314 in.)

2. Engine Valve Seat Location Diameter (C) standard:

Intake

43.0 mm (1.693 in.)

Exhaust

43.0 mm (1.693 in.)

Diameter (C) oversize:

Intake

43.2 mm (1.701 in.)

Exhaust

43.2 mm (1.701 in.)

Depth (D) :

Intake

11.2 mm (0.441 in.)

Exhaust

11.2 mm (0.441 in.)

Seat bottom radius (R):

Intake, maximum

0.8 mm (0.032 in.)

Exhaust, maximum

0.8 mm (0.032 in.)

25

26

2. Engine

Valve Guides Specification

Wear tolerance

83.4 mm (3.283 in.)

-

83.4 mm (3.283 in.)

-

8 mm (0.315 in.)

-

8 mm (0.315 in.)

-

26.5 ± 0.4 mm (1.043 ± 0.016 in.)

-

26.5 ± 0.4 mm (1.043 ± 0.016 in.)

-

Length:

Intake Exhaust Inner diameter:

Intake Exhaust Height above the cylinder head spring plate:

Intake Exhaust Clearance, valve stem - guide: 1

1

Intake

< 0.2 mm (0.008 in.)

Exhaust

< 0.2 mm (0.008 in.)

Measurements are calculated for the method described in Service Information, group 21.

2. Engine Valve Springs Intake (left-hand coil)

Length (unloaded)

73 - 74 mm (2.87 - 2.91 in.)

590 Nm (435 ft-lb) load

58 mm (2.28 in.)


45 mm (1.77 in.)

Butt length max

40 mm (1.57 in.)

Exhaust

Outer valve spring (left-hand coil): Length (unloaded)

73 - 74 mm (2.87 - 2.91 in.)


58 mm (2.28 in.)

1150 (850 ft-lb) Nm load

45 mm (1.77 in.)

Butt length max

40 mm (1.57 in.)

Inner valve spring (right-hand coil):

Length (unloaded)

70 - 71 mm (2.76 - 2.80 in.)


54 mm (2.13 in.)


41 mm (1.61 in.)

Butt length max

37 mm (1.46 in.)

Rocker Arms Bearing play, maximum

< 0.1 mm (0.0039 in.)

Rocker arm roller, play, maximum

< 0.1 mm (0.0039 in.)

27

28

2. Engine

Timing Gears and Camshaft Timing Gear Wheels Backlash

0.05 - 0.17 mm (0.002 - 0.007 in.)

Shaft journal for intermediate gear, diameter

99.99 ± 0.01 mm (3.937 ± 0.0004 in.)

Bushing for intermediate gear, diameter

100.04 ± 0.01 mm (3.939 ± 0.0004 in.)

Diametrical clearance for intermediate gear

max 0.07 mm (0.003 in.)

Axial clearance for intermediate gear

max 0.17 mm (0.007 in.)

2. Engine

C2001718

Number of teeth:

1

Drive gear, crankshaft

38

2

Intermediate gear, coolant pump

83

3

Drive gear, coolant pump

27

4

Drive gear, air compressor

29

5

Drive gear, camshaft

76

6

Intermediate gear (adjustable)

97

7 Drive gear, power steering pump

23

8

Drive gear, (pulley and fuel pump)

27

9

Intermediate gear

71

10

Drive gear, hydraulic pump

39

11

Drive gear, lubrication oil pump

23

12

Intermediate gear, lubrication oil pump

44

29

30

2. Engine

Camshaft Checking camshaft settings, cold engine and valve clearance, cylinder 1 = 0. The intake valve for cylinder 1 for flywheel position 6 after TDC must be open 1.6 ± 0.3 mm (0.064 ± 0.012 in.). When checking, the timing gears must be turned in the correct direction (clockwise viewed from front) to eliminate any backlash.

Specification

Wear tolerance

Drive

Gear

-

Number of bearings

7

-

Diameter bearing journals, standard

69.97-70.00 mm (2.754 - 2.760 in.)

-

Note: Use only to check values, not for machining. Diameter bearing journals, undersize: -

0.25

69.72 - 69.78 mm (2.746 - 2.747 in.)

-

0.50

69.47 - 69.53 mm (2.735 - 2.737 in.)

-

0.75

69.22 - 69.28 mm (2.725 - 2.728 in.)

-

Max axial play

0.35 mm (0.014 in.)

Max permitted out-of-roundness (with new bearings)

0.05 mm (0.0019 in.)

Bearing, permitted wear diametrical

0.05 mm (0.0019 in.)

Valve lift:

Intake

13.1 mm (0.52 in.)

-

Exhaust (VEB)

13.1 mm (0.52 in.)

-

Exhaust (EPG)

12.0 mm (0.47 in.)

-

Decompression and charge profiles (VEB)

1.1 mm (0.043 in.)

-

Permitted wear for the complete cam profile Unit injector, stroke

< 0.1 mm (0.0039 in.) 17 mm (0.67 in.)

-

2. Engine

Camshaft bearing thickness, standard

31

1.92 mm (0.075 in.)

Oversize:

0.25

2.04 mm (0.079 in.)

0.50

2.17 mm (0.087 in.)

0.75

2.29 mm (0.091 in.)

Crankshaft Length

1203 mm (47.36 in.)

Crankshaft axial clearance 1

0.10 - 0.40 mm (0.0039 - 0.0158 in.)

Main bearing radial clearance

1

1

0.046-0117mm (0.0018-0.0046 in.)

Out-of-round, main bearing and connecting rod bearing pins, maximum

0.08 mm (0.0031 in.)

Taper on main bearing and connecting rod bearing pins, maximum

0.05 mm (0.0020 in.)

Run-out of the center bearing, maximum

0.15 mm (0.0059 in.)

Measurements assume lubricated component.

32

2. Engine

Main Bearing Journals (Use only for check values, not for machining.) Diameter (ø) standard

108.0 mm (4.25 in.)

Undersize:

0.25 mm (0.01 in.)

107.73 - 107.75 mm (4.2413 - 4.2421 in.)

0.50 mm (0.02 in.)

107.48 - 107.50 mm (4.2315 - 4.2323 in.)

0.75 mm (0.03 in.)

107.23 - 107.25 mm (4.2216 - 4.2224 in.)

1.00 mm (0.04 in.)

106.98 - 107.0 mm (4.2118 - 4.2125 in.)

1.25 mm (0.05 in.)

106.73 - 106.75 mm (4.2020 - 4.2028 in.)

Surface finish, main bearing journal

R a 0.25

Surface finish, radius

R a 0.4

Width, thrust bearing journals (A), standard

47.0 mm (1.850 in.)

Oversize:

0.2 mm (0.008 in.), axial bearing 0.1 mm (0.004 in.)

47.175 - 47.225 mm (1.8573 - 1.8593 in.)


47.375 - 47.425 mm (1.8652 - 1.8671 in.)


47.575 - 47.625 mm (1.8730 - 1.8750 in.)

Fillet radius (R)

3.75 - 4.00 mm (0.148 - 0.157 in.)

2. Engine

Main Bearing Shells Outer diameter (C)

113.05 mm (4.445 in.)

Thickness (D), standard

2.29 mm (0.098 in.)

Oversize:

0.25 mm (0.01 in.)

2.6 — 2.7 mm (0.102 — 0.106 in.)

0.50 mm (0.02 in.)

2.7 — 2.8 mm (0.106 — 1.110 in.)

0.75 mm (0.03 in.)

2.8 — 2.9 mm (0.110 — 0.114 in.)

1.00 mm (0.04 in.)

22.9 — 3.0 mm (0.114 — 0.118 in.)

1.25 mm (0.05 in.)

3.1 — 3.2 mm (0.122 — 0.126 in.)

Thrust Washers (Axial Bearings) Width (B) standard

3.1 — 3.2 mm (0.122 — 0.126 in.)

Oversize:

0.1 mm

3.2 — 3.3 mm (0.126 — 0.130 in.)

0.2 mm

3.3 — 3.4 mm (0.130 — 0.134 in.)

0.3 mm

3.4 — 3.5 mm (0.134 — 0.138 in.)

33

34

2. Engine

Connecting Rods

T2019085 T2012874

“FRONT” on the shaft is turned forward. Connecting rod and cap are marked as a pair with a three-figure serial number.

1

Length center - center (E)

260 mm (10.236 in.)

Connecting rod bushing internal diameter (G)

55 mm (2.165 in.)

Axial clearance, connecting rod - crankshaft, maximum 1:

0.25 mm (0.0059 in.)

Connecting rod bearing, radial clearance, maximum 1:

0.10 mm (0.0039 in.)

Out-of-true, max deviation on measuring length of 100 mm (330 ft)

0.06 mm (0.0024 in.)

Torsion, max deviation on measuring length of 100 mm (330 ft)

0.15 mm (0.0059 in.)

Measurements are with lubrication.

2. Engine

Connecting Rod Bearing Pins (Only for check values, not machining) Diameter (ø) standard

92.0 mm (3.62 in.)

Undersize: 0.25 mm (0.01 in.)

91.73 - 91.75 mm (3.611 - 3.612 in.)

0.50 mm (0.02 in.)

91.48 - 91.50 mm (3.601 - 3.602 in.)

0.75 mm (0.03 in.)

91.23 - 91.25 mm (3.592 - 3.593 in.)

1.00 mm (0.04 in.)

90.98 - 91.00 mm (3.582 - 3.583 in.)

1.25 mm (0.05 in.)

90.73 - 90.75 mm (3.572 - 3.573 in.)

Surface finish, connecting rod bearing journal

Ra 0.25

Surface finish, radius

Ra 0.4

Width (A)

56.9 - 57.0 mm (2.240 - 2.244 in.)

Fillet radius (R)

3.75 - 4.00 mm (0.148 - 0.157 in.)

35

36

2. Engine

Connecting Rod Bearing Shells Outer diameter (B)

96.85 mm (3.813 in.)

Thickness (C), standard

2.39 — 2.40 mm (0.0941 — 0.094 in.)

Oversize:

0.25 mm (0.01 in.)

2.51 — 2.52 mm (0.0988 — 0.0992 in.)

0.50 mm (0.02 in.)

2.64 — 2.65 mm (0.1039 — 0.1043 in.)

0.75 mm (0.03 in.)

2.76 — 2.77 mm (0.1087 — 0.1090 in.)

1.00 mm (0.04 in.)

2.89 — 2.90 mm (0.1138 — 0.1141 in.)

1.25 mm (0.05 in.)

3.01 — 3.02 mm (0.1185 — 0.1188 in.)

Diameter, bearing shell bearing seat (D)

96.84 — 96.85 mm (3.8126 — 3.8129 in.)

Flywheel Axial run-out (manual gearbox) measurement radius 150 mm (5.91 in.), maximum

0.20 mm (0.008 in.)

Number of teeth on starter motor gear ring

153

Sensor groove in flywheel

3 x 18

Flywheel Housing, Installed Permitted axial runout for mating surface against clutch housing, maximum

0.20 mm (0.008 in.)

Permitted axial runout for location against clutch housing, maximum

0.25 mm (0.010 in.)

2. Engine

37

Lubrication and Oil Systems Oil Pressure Operating speed (above 1100 rpm)

300-550 kPa (45 - 80 psi)

Idle speed, minimum

150 kPa (22 psi)

Oil Pressure, Rocker Arm Shaft Non-activated VEB

100 kPa (15 psi)

Activated VEB

min. 200 kPa (min. 30 psi)

Oil Temperature Warm engine (running); coolant temperature 75 - 95 (167 - 203 F) 1

C 65 - 105

C (149 - 221

F) 1

Up to 125 C (257 F) at high engine load

Oil Pump Type

Gear driven

Number of teeth:

Drive gear

23

Intermediate gear

44

Diameter:

Hub, intermediate gear

69.99 ± 0.01 mm (2.7555 ± 0.0004 in.)

Bushing, intermediate gear

70.04 ± 0.02 mm (2.7575 ± 0.0008 in.)

Axial clearance:

Drive gear, pump

0.11 mm (0.0043 in.)

Intermediate gear

0.10 mm (0.0039 in.)

Backlash

0.05 - 0.17 mm (0.0020 - 0.0067 in.)

Distance, drive gear — oil housing bracket

1.0 - 2.4 mm (0.0394 - 0.9449 in.)

38

2. Engine

Oil Filter Number

Full-flow filter (is tightened 1/2 - 3/4 turn after contact)

2

Fine filter (is tightened 3/4 - 1 turn after contact)

1

Oil Valves

T2012843

1. Safety valve

Marking

Yellow

2. Control valve, oil cooler (bypass valve)

(A) Marking

124

3, 5. Overflow valve, oil filter

Spring, free length

69 mm (2.72 in.)

With a load of 13 - 15 Nm

40 mm (1.57 in.)

4. Piston cooling valve

Marking

Orange

6. Reduction valve

Marking

Blue

2. Engine

39

Fuel System Fuel Pump Fuel pressure at:

600 rpm

> 100 kPa (15 psi)

1400 rpm

> 300 kPa (45 psi)

full load

> 300 kPa (45 psi)

Overflow Valve Opening pressure

360 - 420 kPa (53.6 - 62.5 psi)

Unit Injector

T2012878

Tighten the adjustment screw to zero clearance on the camshaft, then turn an additional 3 - 4 flats (180 — 240 ).

Preload setting, 3 - 4 flats (see illustration) ...............................................

0.75 ± 0.1 mm (0.0295 ± 0.0039 in.)

Cylinder Balancing Cylinder balancing, VCADS Compensation, maximum

± 80%

40

2. Engine

Intake and Exhaust System Turbocharger Axial clearance turbine rotor shaft, maximum

0.1 mm (0.0039 in.)

2. Engine

41

Minimum Charge Air Pressure at 100% Engine Load Minimum @ 100% engine load

Pins EA22 (signal) & EA11 (sensor ground)1

Response Values2

1200 rpm

125 kPa (18.1 psi)

2.57 V

3.5 - 4.5 sec

1400 rpm

176 kPa (25.5 psi)

3.12 V

3.5 - 4.5 sec

1600 rpm

183 kPa (26.5 psi)

3.21 V

3.5 - 4.5 sec

1800 rpm

187 kPa (27.1 psi)

3.25 V

3.5 - 4.5 sec

1200 rpm

140 kPa (20.3 psi)

2.73 V

4.5 - 5.5 sec

1400 rpm

180 kPa (26.1 psi)

3.18 V

3.5 - 4.5 sec

1600 rpm

187 kPa (27.1 psi)

3.26 V

3.5 - 4.5 sec

1800 rpm

193 kPa (28 psi)

3.32 V

3.5 - 4.5 sec

1200 rpm

145 kPa (21 psi)

2.88 V

4.5 - 5.5 sec

1400 rpm

185 kPa (26.8 psi)

3.23 V

3.5 - 4.5 sec

1600 rpm

193 kPa (28 psi)

3.32 V

3.5 - 4.5 sec

1800 rpm

199 kPa (28.9 psi)

3.39 V

3.5 - 4.5 sec

1200 rpm

153 kPa (22.2 psi)

2.88 V

4.5 - 5.5 sec

1400 rpm

190 kPa (27.5 psi)

3.29 V

4 - 5 sec

1600 rpm

205 Kpa (29.7 psi)

3.46 V

3.5 - 4.5 sec

1800 rpm

206 kpa (29.9 psi)

3.47 V

3.5 - 4.5 sec

1200 rpm

175 kPa (25.3 psi)

3.12 V

4 - 5 sec

1400 rpm

206 kPa (29.9 psi)

3.47 V

3.5 - 4.5 sec

1600 rpm

224 Kpa (32.5 psi)

3.67 V

3.5 - 4.5 sec

1800 rpm

226 Kpa (32.8 psi)

3.69 V

3.5 - 4.5 sec

D12D365:

D12D395:

D12D425:

D12D435:

D12D465:

1

Test run with normal diesel fuel (type 2) and below 1500 m (4500 ft.) altitude.

2

Response times from 0 kPa (0 psi) charge air pressure to 90% of max charge air pressure.

42

2. Engine

Charge Air Temperature Sensor Cold engine (off)

Ambient temperature

Warm engine (running, vehicle standing still); coolant temperature 75 - 95 C (167 - 203 F)

10 - 30 C (50 - 86 F) above ambient temperature

Exhaust Pressure Governor (EPG)

T2013094

EPG travel (A), minimum

29 mm (1.14 in.)

2. Engine

43

Heat Retention Function Air pressure for exhaust pressure governor (EPG)

155 ± 8 kPa (23 ± 2 psi)

Heat retention activated:

Coolant temperature (minimum)

< 70 — 80

Engine load

< approx. 50% 1

Accelerator pedal

at rest (released)

C/ —4

(158 – 176

F /— 2

)

Heat retention deactivated:

1

Coolant temperature

> 70

Engine load

> approx. 50%

Accelerator pedal

off idle (depressed)

C (158

F)

Engine load could be more or less depending on engine speed. Check should be made with engine at idle speed.

44

2. Engine

EPG Activation for Idle EGR Air pressure for exhaust pressure governor (EPG)

approx. 100 kPa (14.5 psi)

Activation:

1

Coolant temperature

> 65

Clutch pedal

at rest (released)

Accelerator pedal

at rest (released)

Engine speed

idle

Ambient temperature

>4

EGR temperature

> 98

C (> 149

C ( > 25 C ( > 208

F)

F) F) 1

Idle EGR is active when all conditions listed are met. After the first 3 minutes of idle time, the EMS reads the EGR temperature. If below 98 C (208 F), idle EGR is not active. If above value, it remains active. Check parameter AZN in MID 128 (Engine ECU).

2. Engine

45

Engine Brake EPG Inlet Pressure Note: Checks should be made with oil temperature greater than 55 C (131 F)

T0008637

Braking force in % 1 Pressure of EPG in kPa (psi)

Exhaust brake only

Engine brake, switch position 1 1

100% (high)

Cruise mode

750 kPa (109 psi)

50 - 750 kPa (7 - 109 psi)

2–way switch can give 100% (high) EPG only

T0008058

VEB

1 2

Brake force in % 1 Pressure of EPG in kPa (psi)

EPG VCB

50% (low)

100% (high)

Cruise mode 2

VEB Switch position 1

750 kPa (109 psi)

–

50 — 750 kPa (7 — 109 psi)

On

Off

VEB switch position 2

750 kPa (109 psi)

750 kPa (109 psi)

50 — 750 kPa (7 — 109 psi)

On

On

3–way switch can give 50% (low) or 100% (high) EPG and VCB Cruise control overspeed protection. Engine brake activation. parameter AF in VECU MID 144

46

2. Engine

EPG

Activated: engine speed

> 900 rpm

vehicle speed

> 5 km/h (3 mph)

Deactivated: engine speed

< 800 rpm

vehicle speed

< 5 km/h (3 mph)

VCB Activated:

engine speed 1

> 1100 rpm

vehicle speed

> 5 km/h (3 mph)

engine oil temperature

> 55

C (131

F) 2


> 60

C (140

F) 3

charge air pressure

< 50 kPa (7 psi)

Deactivated:

1

2 3

engine speed1

< 1000 rpm

vehicle speed

< 5 km/h (3 mph)


< 55

charge air pressure

> 70 kPa (10 psi)

C (131

F)

The value is increased to 1400 rpm for the first five activations. Applies at engine oil temperatures 55 82 C (131 - 180 F). Oil temperature sensor combined with oil pressure sensor Oil temperature sensor combined with oil level sensor in oil pan

2. Engine Exhaust Backpressure

1

Standard muffler, maximum

15 kPa (2.18 psi) (4.4 in. Hg)

Tuned muffler (D12D-465), maximum 1

20 kPa (2.9 psi) (6 in. Hg)

Oct. 02 - Jan. 04

Cooling System For cooling system volumes and coolant requirements, refer to Service Information, group 18: “Coolant Requirements, Volvo Engines.”

General Pressure valve opens at

75 kPa

(10.9 psi)

Fan Viscous Fan (Air Sensing Fan) Speed, engaged (engine speed @ 1800 rpm)

Fan pulley diameter 167 mm (6.57 in.)

2400 rpm


2150 rpm


1900 rpm

Speed, not engaged

500 - 1000 rpm

Engagement temperature

75

C (167

F) in front of fan

47

48

2. Engine

Electronically Controlled Viscous Fan Activated system

Condition

Coolant temperature

Start temperature 90 (194 F)

Coolant temperature

> 93

Engine ECU temperature

Activation ECU temperature > 100 C (212 F), deactivates < 95 C (203 F)

1200 rpm

AC system

Refrigerant pressure > 20 bar (300 psi)

Full engagement (120% of engine speed) example engine speed 1500 rpm x 120% = 1800 approx. fan speed

Engine speed > 1500 rpm, ambient temp > 40 C (104F), vehicle speed < 45km/h (28 mph)

1200 rpm

Engine speed > 1200 rpm, ambient temp > 30 C (86F), vehicle speed < 45km/h (28 mph)

1000 rpm

Ambient temp > 35 C (95F), vehicle speed < 10km/h (6 mph)

1200 rpm

Ambient temp > 20 C (68F), vehicle speed < 20km/h (12 mph)

600 rpm

AC system (a/c compressor magnetic clutch activated)

Fan RPM Requested

C

C (199F)

600 rpm Variable fan speed activation

2. Engine

49

On-off Fan Activation temperature

91

C (196

F)

Deactivation temperature

87

C (189

F)

Activated System

Condition

Coolant temperature

Activation > 91 F)

Engine ECU temperature

ECU temperature > 100 C (203 F)

Intake manifold air temperature (VHD 465 hp only)

> 80 C(176 F) for more than 2.5s, deactivates below 70 C(158 F) for more than 5s

AC system

Refrigerant pressure > 20 bar (300 psi)

Thermostat Quantity

1

Opening temperature

82

C (179

F)

C (196

F), deactivation 87 C (212

C (189

F), deactivates < 95

50

2. Engine

Engine Control System Engine ECU Note: The EECU may not be replaced without prior authorization from Volvo; refer to Service Information, Engine ECU, Fault tracing, IMPACT or ID DVD: Info type “Diagnostics” group 2841.

Number of pins

2 x 62

Sensors Charge air sensor Check value

1.05 — 1.30 V (normal atmospheric pressure)

Intake air temperature sensor

T2019008

2. Engine

Coolant temperature sensor

T2019009

51

52

2. Engine

Intake temperature sensor

T2019010

2. Engine

Engine oil temperature sensor

T2019011

Camshaft sensor Distance to camshaft

0.3 - 1.0 mm (0.012 0.039 in.)

Resistance measurement

775 - 945

Flywheel sensor Distance to flywheel

0.7 - 2.1 mm (0.028 0.083 in.)

Resistance measurement

775 - 945

53

54

2. Engine

Crankcase Pressure Sensor Sensor alarm limit

> 8 kPa (1.2 psi)

Crankcase pressure: normal value (VEB not active) regardless of engine speed, maximum

1.0 kPa (0.13 psi)‘

2. Engine

55

Tightening Torques and Patterns Group 20 Tightening

M6 standard screw 8.8

10 ± 1.5 7.4 ± 1 Nm (89 ± 13 inch-lb)


24 ± 4 Nm (18 ± 3 ft-lb)


48 ± 8 Nm (35 ± 6 ft-lb)


85 ± 15 Nm (63 ± 11 ft-lb)


140 ± 25 Nm (103 ± 18 ft-lb)


190 ± 35 Nm (140 ± 26 ft-lb)

Only torque-tightened screws may be reinstalled. Torque and angle tightened / yield point screws:

8.8

must not be reinstalled

10.9

may be reinstalled

12.9

may be reinstalled

Note: Check the screw that is being reinstalled. A damaged screw (e.g. with tear damage under the head) must be replaced.

56

2. Engine

Group 21 Tightening:

Torque

Front engine mounting, cylinder block

175 ± 20 Nm (129 ± 15 ft-lb

Front engine mounting, crossmember

85 ± 15 Nm (63 ± 11 ft-lb)

Rear engine mounting, flywheel casing

245 ± 35 Nm (181 ± 27 ft-lb)

Angle

Rear engine mounting, rubber cushion step 1

175 ± 5 Nm (129 ± 4 ft-lb)

step 2

255 ± 38 Nm (188 ± 28 ft-lb)

Main bearing cap step 1

150 ± 20 Nm (110 ± 15 ft-lb)

step 2

120 ± 5

Connecting rod cap step 1

275 ± 15 Nm (204 ± 11 ft-lb)

2. Engine

T2014149

Stiffening frame, tightening sequence

Tightening:

Torque

Angle

Stiffening frame

step 1: tighten screws 1-6 in sequence

48 ± 8 Nm (36 ± 6 ft-lb)

step 2: tighten screws 7-26 in sequence

15 Nm (11 ft-lb)

Piston cooling valve, screw 1 1

screws may not be reused.

24 ± 4 Nm (18 ± 3 ft-lb)

90 ± 5

57

58

2. Engine

T2006973

Flywheel, tightening sequence (ensure that flange is dry and clean).

Tightening:

Torque

Angle

Flywheel (tighten screws in numerical order as illustrated):

step 1 step 2

60 ± 5 Nm (44 ± 4 ft-lb) 60 ± 5

2. Engine

T2019062

Flywheel housing, tightening sequence.

Tightening:

Torque

Flywheel housing

140 ± 14 Nm (105 ± 10 ft-lb)

Note: Apply a string of silicone as illustrated, thickness 2 mm (0.08 in.), max. 20 minutes before assembly.

Angle

59

60

2. Engine

T2014027

Vibration damper, VN — tightening sequence.

Tightening:

W2004219

Vibration damper, VHD — tightening sequence.

Torque

Angle

Vibration damper

step 1 1 .......................................................

20 ± 5 Nm (15 ± 4 ft-lb)

step 2 .........................................................................................................

90 ± 5

Note: Screws may NOT be reused if they have been tightened with torque and angle. 1

Following the numerical order, tighten screws according to step 1 before tightening according to step 2.

2. Engine

61

T2012845

Valve cover, tightening sequence

Note: If the valve cover is replaced, a new Engine Certification Label must be printed and affixed to the new valve cover. A new label can be printed from VCADS Pro “Engine Label Print” group 2. Tightening:

Torque

Valve cover (tighten screws in order as illustrated)

20 ± 2 Nm (15 ± 1.5 ft-lb)

Stud, valve cover

40 ± 3 Nm (29 ± 2 ft-lb)

62

2. Engine

T2007004

Cylinder head, tightening sequence

Tightening:

Torque

Angle

Cylinder head (tighten screws in order as illustrated):

step 1

60 ± 10 Nm (44 ± 7 ft-lb)

step 2 (check tightening)

60 ± 10 Nm (44 ± 7 ft-lb)

step 3

90 ± 5

step 4 (turn additional)

90 ± 5

Cleaning plug, cylinder head

60 ± 10 Nm (44 ± 7 ft-lb)

Lock nut, valve adjustment screw:

Option 1 Option 2

38 ± 4 Nm (28 ± 3 ft-lb) 60 ± 5 after contact

Lock nut, valve yoke (EPG)

60 ± 5 after contact

Lock nut, valve yoke (VEB)

60 +10/-0 after contact

2. Engine

T2012850

Bearing cap, camshaft/rocker arm shaft, tightening sequence

Tightening:

Torque

Angle

step 1

15 ± 5 Nm (11 ± 4 ft-lb)

90 ± 5

step 2 1

60 ± 5 Nm (44 ± 4 ft-lb)

step 3

15 ± 5 Nm (11 ± 4 ft-lb)

120 ± 5

15 ± 5 Nm (11 ± 4 ft-lb)

120 ± 5

Bearing cap, camshaft/rocker arm shaft

step 4 (loosen the screws) step 5 1

Screws must be tightened in stages to ensure that the rocker arm shaft comes down without bending.

63

64

2. Engine

T2019046

Timing gear cover, lower

Tightening:

Torque

Timing gear cover, lower: Step 1: Apply a thin bead 1 of silicone as illustrated, including around the marked hole no more than 20 minutes before assembly. Step 2: Working from center outward, tighten to 1

Solid line = 2 mm bead; dashed line (area A) = 1 mm bead.

34 ± 4 Nm (24 ± 3 ft-lb)

2. Engine

T2019925

Timing gear cover, upper Note: When the upper timing gear cover is installed, the top section must

be flush with the cylinder head.

Tightening:

Torque

Timing gear cover, upper: Step 1: Apply a thin bead of silicone 1 as illustrated, including around the marked holes, no more than 20 minutes before assembly. Step 2: Tighten screws in order as illustrated:

1

M8

24 ± 4 Nm (18 ± 3 ft-lb)

M10

48 ± 8 Nm (36 ± 6 ft-lb)

Thickness 2 mm.

65

66

2. Engine

W2004477

Gear train

Timing gears: use the following torques (and angles, when indicated) for the

corresponding gear; follow the tightening sequence for each gear as illustrated.

Tightening:

Torque

Angle

A.

Camshaft gear

35 ± 3 Nm (26 ± 2 ft-lb)

90 ± 5

B.

Adjustable idler (intermediate) gear

15 ± 3 Nm (11 ± 2 ft-lb)

120 ± 5

C.

Intermediate gear

15 ± 3 Nm (11 ± 2 ft-lb)

120 ± 5

D.

Idler/intermediate gear

24 ± 4 Nm (18 ± 3 ft-lb)

E.

Crankshaft gear (polygon hub)

645 ± 25 Nm (476 ± 18 ft-lb)

F.

Idler gear

15 ± 3 Nm (11 ± 2 ft-lb)

120 ± 5

2. Engine

Group 22

T2017885

Oil pan, tightening sequence

Tightening:

Torque

Oil pan (tighten bolts in order as illustrated)

24 ± 3 Nm (18 ± 2 ft-lb)

Drain plug, oil pan

60 ± 10 Nm (44 ± 7 ft-lb)

Bracket, oil pump/main bearing cap

24 ± 3 Nm (18 ± 2 ft-lb)

Oil strainer, mounting screws in pump

27 ± 3 Nm (20 ± 2 ft-lb)

Oil cooler, mounting screws

27 ± 3 Nm (20 ± 2 ft-lb)

67

68

2. Engine

T2006825

T2006701

Delivery pipe

Delivery Pipe

Torque

Angle

Step 1:

Tighten fitting in cylinder block until it bottoms; approximately

10 Nm (88 in-lb)

Step 2:

New pipe

180

Pipe being reinstalled

60

2. Engine

T2014088

Oil cooler, cover; always use guide pins when installing the cover on the engine.

Tightening:

Torque

Oil cooler, cover

Mount screws A and B

24 ± 4 Nm (18 ± 3 ft-lb)

Tighten C and D

24 ± 4 Nm (18 ± 3 ft-lb)

Tighten cover screws in numerical order from the middle outwards (1–4); see illustration

24 ± 4 Nm (18 ± 3 ft-lb)

Check tighten screws A and D

24 ± 4 Nm (18 ± 3 ft-lb)

69

70

2. Engine

Group 23 Tightening:

Torque

Angle

Retainer, unit injector (new copper sleeve) First tightening

step 1

20 ± 5 Nm (15 ± 4 ft-lb)

step 2

180 ± 5

Loosen the retainer screw before the second tightening. Second tightening

step 1

20 ± 5 Nm (15 ± 4 ft-lb)

step 2

60 ± 5

Retainer, unit injector (reused copper sleeve)

step 1

20 ± 5 Nm (15 ± 4 ft-lb)

step 2

60 ± 5

Lock nut for adjustment screw, unit injector:

Option 1

52 ± 4 Nm (38 ± 3 ft-lb)

Option 2

45 ± 5

Banjo screw, 10 mm

12 ± 2 Nm (108 ± 22 inch-lb)

Banjo screw, 14 mm

35 ± 4 Nm (26 ± 3 Ft-lb)

Banjo screw, 16 mm

40 ± 5 Nm (30 ± 4 ft-lb)

2. Engine Group 25

W2004483

Exhaust manifold

Exhaust manifold (refer to illustration for tightening sequence):

Torque

1.

Tighten bolts 1 to maximum

10 Nm (88 inch-lb)

2.

Tighten bolts 2 to maximum

10 Nm (88 inch-lb)

3.

Tighten bolts 3 to

52 ± 4 Nm (38 ± 3 ft-lb)

4.

Tighten bolts 2 to

52 ± 4 Nm (38 ± 3 ft-lb)

5.

Tighten bolts 4 to

52 ± 4 Nm (38 ± 3 ft-lb)

6.

Tighten bolts 1 to

52 ± 4 Nm (38 ± 3 ft-lb)

Tightening

Torque

Clamp, exhaust manifold (“A” in illustration)

10 ± 1 Nm (71 ± 8 inch-lb)

Exhaust pressure governor (EPG) turbine housing

24 ± 2 Nm (18 ± 1.5 ft-lb)

Control valve (VEB)

20 ± 3 Nm (15 ± 2 ft-lb)

Nut electrical connector, VEB-valve

1.5 ± 0.5 Nm (13 ± 4 inch-lb)

V-clamp, turbocharger housing

8.5 Nm (75 inch-lb)

71

72

2. Engine

EGR System

W2004292

Tightening

Torque

EGR Pipes:

V-clamp

10 ± 2 Nm (88 ± 17 inch-lb)

Hose clamp, mixing chamber

5 ± 1 Nm (35 ± 9 inch-lb)

Vibration Damper Assembly:

Bracket

15 ± 3 Nm (133 ± 3 inch-lb)

Vibration Damper

24 ± 4 Nm (18 ± 3 ft-lb)

2. Engine

73

W2004261

Tightening sequence for EGR cooler mounting brackets

Note: Older version shown. Newer engine version “number 1” in the image has been

removed. Front and rear bracket are the same on newer engines.

Tightening Sequence

Torque

EGR cooler mounting bracket, rear tensioning band:

1.

Screw (against washer)

24 ± 4 Nm (18 ± 3 ft-lb)

2.

Screw/lock nut

12 ± 2 Nm (106 ± 17 inch-lb)

EGR cooler mounting bracket, front tensioning band:

3.

Screw/lock nut

12 ± 2 Nm (106 ± 17 inch-lb)

Group 26 Thermostat, mounting bolts

Torque

Bolt grade 8.8

24 ± 4 Nm (18 ± 3 ft-lb)

Bolt grade 10.9

30 ± 4 Nm (22 ± 3 ft-lb)

74

3. Electrical System and Instruments

Specifications Fuse and Relay Locations The vehicle’s instrumentation, gauges and other electrically controlled parts are wired through the Truck Electrical Center (TEC). The TEC is located in the center of the dash, just above the engine cover. The vehicle has two electrical centers, one located in the middle of the dash under the top cover, and the other under the front cover. The electrical center underneath the front cover is the power module and it feeds the relays to the electrical center under the top cover. Located just below the fuse/relay panel are the following modules: Vehicle ECU/Bodybuilder module, Light Control Module, Steering Wheel Module and Central Locking Module/relay. Refer to the decal inside the TEC cover for vehicle’s exact fuse locations and ratings. (Note that all fuses and relays may not be used in every vehicle.) The TEC panel includes all maxi-fuses, mini-fuses, relays and micro-relays. Maxi-fuses are designed for larger amounts of current than regular fuses. The micro ISO relays are smaller in size than conventional relays, and the pin arrangement is different. Mini-fuses are also smaller in size, but the current rating is the same as ATO-size fuses.

W3005285

TEC in Center Dash

3. Electrical System and Instruments Tightening Torques

Delco 42MT 1 Solenoid 2 Shift Lever Housing 3 Nose Housing 4 Pinion 5 Overcrank Protection Input Connector

Melco Gear Reduction

Delco 39 MT HD

1 Solenoid 2 Heavy-duty Relay 3 Pinion

Starter solenoid stud nut

30.5 ± 3.5 Nm (22 ± 2.6 ft-lb)

25 ± 5 Nm (18 ± 3.7 ft-lb)

26 ± 1.5 Nm (19 ± 1.1 ft-lb)

Starter ground stud

30.5 ± 3.5 Nm (22 ± 2.6 ft-lb)

25 ± 5 Nm (18 ± 3.7 ft-lb)

26 ± 1.5 Nm (19 ± 1.1 ft-lb)

Battery cables (+ and -)

19 ± 1Nm (14 ± 1 ft-lb)

Main power studs (at cab passthrough)

10 ± 2 Nm (88 ± 17 in-lb)

Main ground studs (at cab passthrough)

10 ± 2 Nm (88 ± 17 in-lb)

75

76


Torque Specifications for Ring Terminals Cab 12V Power Connections

Pass-through power stud

Torque Specification

10 ± 2 Nm (89 ± 18 in-lb)

Engine Block

Engine block ground

19 ± 1 Nm (14 ± 0.7 ft-lb)

Starter Motor

Main power and ground

30.5 ± 3.5 Nm (22.5 ± 2.6 ft-lb)

Solenoid stud (Delco 42MT, Melco)

2.8 ± 0.8 Nm (24 ± 7 in-lb)

Starter—mounted relay (Delco 39 MT HD)

2.25 ± 0.25 Nm (20 ± 2 in-lb)

Alternator (33SI/34SI)

Battery terminal — circuit 8

6.9 ± 0.5 Nm (61 ± 5 in-lb)

Ground terminal — circuit 0A

6.1 ± 0.5 Nm (54 ± 5 in-lb)

“I” terminal — circuit 14

2.4 ± 0.5 Nm (22 ± 5 in-lb)

“R” terminal — circuit 16

2.4 ± 0.5 Nm (22 ± 5 in-lb)

Alternator (22SI)

Battery terminal — circuit 8

6.5 ± 0.5 Nm (58 ± 5 in-lb)

Ground terminal — circuit 0A

6.1 ± 0.5 Nm (54 ± 5 in-lb)

“I” terminal — circuit 14

2.4 ± 0.5 Nm (22 ± 5 in-lb)

“R” terminal — circuit 16

2.4 ± 0.5 Nm (22 ± 5 in-lb)

Preheater Relay)

Power stud

5.7 ± 0.6 Nm (50 ± 5 in-lb)

Coil stud

1.7 ± 0.3 Nm (16 ± 2 in-lb)

Preheater Assembly

Brass Nut

12.5 ± 1.5 Nm (110 ± 13 in-lb)

Flange screw

14.5 ± 1.5 Nm (128 ± 13 in-lb)

Bulkhead

Engine-side ground studs

6 ± 1 Nm (53 ± 8 in-lb)

Starter relay

Power stud

5.7 ± 0.6 Nm (50 ± 5 in-lb)


77

Group 35 — Light Control Module

W3005269

T3014623

The Light Control Module (LCM) controls all exterior lighting functions. Interior lighting in the cab and optional “extras” installed on the vehicle are not part of this system. In addition, it controls the intermittent windshield wiper function and the wiper

function when the windshield washer is used. The control unit communicates via the J1587/1708 information link and the J1939 control data link as MID 216. See “MID 216” page 10

78


Light Switch

W3005328

1. Light Switch 2. Hazard Warning lights switch/Hazard warning lights indicator light 3. Rheostat for instrument lighting A. “Off” B. Park C. Drive D. Drive+ Note: Only premium version have

the “Drive+” position.


79

W3005328

Light Switch Troubleshooting The LCM operates by interpreting a combination of ground and open signals from terminals 1 & 2 on the back of the Light Switch. To test switch functions • Set multimeter to Ohms (resistance) • Connect black lead of multimeter to terminal 16 (ground). • Probe terminals 1 or 2 with the red lead. The chart below demonstrates the expected meter readings by switch position and terminal. Position

Terminal 1

0ff (A) Parking lights (B) Headlights (C) Headlights with auxillary lights (D)

Open

Function 2

≈

0

Daytime running lights

≈

0

Daytime running lights, Tail lights, Parking lights, Side marker lights

Open

Open

High beam / low beam, Tail lights, Parking lights, Side marker lights

0

Open

High beam / low beam, Auxiliary lights (driving/fog), Tail lights, Parking lights, Side marker lights

≈

≈

0

80

5. Brakes

Specifications Drum Brake Brake Slack Adjusters and Cam

W5001492

DANGER Before checking the slack adjusters, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury of death. To check the slack adjusters for proper throw, use a breaker bar to lever the slack adjuster out. Measure the distance of the travel. It should not exceed 25 – 30 mm (1 – 1.25 in) for a 6 inch slack adjuster and should not exceed 20 — 25 mm (.75 — 1 in) for a 5.5 inch slack adjuster. Also make sure that the length of the slack adjuster is the same on an axle. Note: Travel is measured from the chamber face as shown in the illustration.

5. Brakes

81

Brake Linings DANGER Before measuring linings, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury of death.

W7001278

Measure the brake lining thickness, If the brakes are equipped with backing plates, measure through the inspection holes in the plate. Reline the brake shoes if the lining thickness is 6 mm (.25 in) or less at the middle of the shoe. Note: Check the brake drums for and visible cracks or signs of oil or grease.

82

5. Brakes

Compressor 1COMP530

T5012037

Model ........................................................................

WABCO 352

Volvo part no. D12 engine .......................................

20382348

Type ..........................................................................

Piston compressor

Number of cylinders .................................................

1

Cooling, cylinder head ..............................................

Fluid

Cooling, cylinder ......................................................

Air

Air capacity at back pressure of 800 kPa (8 bar) and compressor speed of 2000 rpm .................................

440 dm³/min

Max operating pressure .............................................

1300 kPa (13 bar)

Max operating speed .................................................

3000 rpm

Cylinder bore ............................................................

85 mm (3.34 in.)

Stroke ........................................................................

62 mm (2.44 in.)

Swept volume ...........................................................

352 cm³ (21 in³)

PR function:

Cylinder stroke PR-piston reed valve .......................

10-15 mm (.39-.59 in.)

5. Brakes Tightening Torques Tightening:

Torque - Nm (ft-lb)

Drive gear wheel .......................................

200 - 250 (147 - 184)

Union, outlet pipe .....................................

130 ± 20 (95 ± 14)

Unions for oil hoses, compressor and engine block ..........................................................

25 ± 4 (18 ± 2.9)

Cylinder head bolts, 4pcs (1-4). Refer to illustration below for correct tightening sequence ....................................................

25 ± 2 (18 ± 1.4)

90

Bolted joints, valve plate 4pcs (5-8). Refer to illustration below for correct tightening sequence ....................................................

10 ± 1 (7.3 ± .7)

90

Union, PR connection to compressor .......

25 ± 4 (18 ± 2.9)

Bolted joint, compressor mounting ...........

85±15 (62 ± 11)

T5012871

Angle

83

84

5. Brakes

2COM1080 VERSION2

T5012038

Make .........................................................................

WABCO 704

Volvo part no. D12 engine .......................................

20382347

Type ..........................................................................

Piston compressor

Number of cylinders .................................................

2

Cooling, cylinder head ..............................................

Fluid

Cooling, cylinder ......................................................

Air

Air capacity at back pressure of 800 kPa (8 bar) and compressor speed of 2000 rpm .................................

800 dm³/min

Max operating pressure .............................................

1300 kPa (13 bar)

Max operating speed .................................................

3000 rpm

Cylinder bore ............................................................

85 mm (3.34 in)

Stroke ........................................................................

62 mm (2.44 in)

Swept volume ...........................................................

704 cm³ (43 in³)

PR function:

Cylinder stroke PR-piston reed valve .......................

10-15 mm (.39 - .59 in)

5. Brakes Tightening Torques Tightening:

Torque - Nm (ft-lb)

Angle

Drive gear wheel .......................................

200 - 250 (147 - 184)

Union, outlet pipe .....................................

130 ± 20 (95 ± 14)

Unions for oil hoses, compressor and engine block ..........................................................

25 ± 4 (18 ± 2.95)

Cylinder head bolts 6pcs (1-6).

25 ± 2 (18 ± 1.47)

90

Valve plate bolts 4pcs (7-8). Refer to illustration below for correct tightening sequence ....................................................

7 ± 2 (5 ± 1.47)

90

Nipple, PR connection to compressor .......

25 ± 4 (18 ± 2.95)

Bolted joint, compressor mounting ...........

85 ± 15 (62 ± 11)

Note: After the screws (1-6) are torqued tight, check by turning screw (1) once again.

Refer to illustration below for correct tightening sequence ...................................

T5012835

85

86

5. Brakes

Air Drier Wabco SS1200P Height

284 mm (11.2 in.)

Voltage .....................

12 V

Working Pressure .....

10.3 bar (150 psi)

Maximum flow capacity ...................

1416 L/min (50 cfm)

Heater power ............

100 W

Wabco System Saver Twin Height .......................

322 mm (12.6 in.)

Maximum width .......

320 mm (12.6 in.)

Voltage .....................

12 V

Working Pressure .....

10.3 bar (150 psi)

Maximum flow capacity ...................

1416 L/min (50 cfm)


100 W

Bendix ADIP Height .......................

360 mm (14.18 in.)


235 mm (9.27 in.)

Weight ......................

13 kg (28 lb)

Voltage .....................

12 V

Maximum flow capacity ....................

850 L/min (30 cfm)


90 W

5. Brakes

Bendix AD-9 Height .......................

360 mm (14.25 in.)


235 mm (9.75 in.)

Weight ......................

13 kg (28 lb)

Voltage .....................

12 V or 24 V


481 L/min (17 cfm)


90 W

Midland Pure Air Plus Height .......................

384 mm (15.1 in.)


236 mm (9.31 in.)

Weight ......................

8 kg (18 lb)

Voltage .....................

12 V


710 L/min (25 cfm)


95 W

87

88

5. Brakes

CR Turbo 2000 Height .......................

413 mm (16.25 in.)


216 mm (8.5 in.)

Weight ......................

7.5 kg (16.5 lb)

Voltage .....................

12 V


850 L/min (30 cfm)


75 W

5. Brakes Brake Valves Treadle Valve Main brake actuation valve, foot operated. Make, Model

Bendix, E–6

Max operating pressure

150 PSI (10.3 bar)

Connections, all 3/8” NPTF • Rear brake supply 11, 2 ports • Rear brake delivery 21, 2 ports • Front brake supply 12, 2 ports • Front brake delivery 22, 2 ports

Park Brake Control Valve Dash mounted valve for application and release of park brake system. Single button valve Make

Meritor Wabco


150 PSI (10.3 bar)

Control of park brakes for vehicles not intended to pull trailer. Connections, all Push-To-Connect (PTC) built-in cartridges • Rear circuit air reservoir • Front circuit air reservoir • Exhaust • Air delivery to park brakes

89

90

5. Brakes

(Park Brake Control Valve continued) Dual button valve

Make

Meritor Wabco


150 PSI (10.3 bar)

Control of park brakes for vehicles intended to pull trailer. Connections, all Push-To-Connect (PTC) built-in cartridges • Rear circuit air reservoir • Front circuit air reservoir • Exhaust • Air delivery to truck park brakes • Air delivery to trailer • Auxiliary port (supplies blended air for aux. brake control valves

Hand Control Valve Dash mounted brake application valve generally used to apply trailer brakes Make

Meritor Wabco


150 PSI (10.3 bar)

Pressure delivery

Modulated pressure from 0 to system pressure depending on handle position.

Connections, all Push-to-Connect (PTC) built-in cartridges. • Supply port • Delivery port • Exhaust port

5. Brakes Quick Release Valve For rapid release of brake application air on the front wheels. Make

Meritor Wabco


150 PSI (10.3 bar)

Crack pressure

3 PSI (0.2 bar)

Connections Supply port

1/2” NPTF

Delivery port

3/8” NPTF

Quick Release Valve with Double Check For rapid release of park brake air on the rear wheels. Use for tractors. Make

Meritor Wabco


150 PSI (10.3 bar)

Connections Supply port

1/4” NPTF

Anti-compounding port

1/4” NPTF

Delivery port

3/8” NPTF

91

92

5. Brakes

Inversion Relay Valve For application and release of parking brake. In the event of an emergency due to air pressure loss in the primary air reservoir (rear air brake circuit), this valve allows modulated control of the rear brakes through the spring brake chambers by use of the secondary air control (front brake circuit). Make

Meritor Wabco


150 PSI (10.3 bar)

Max spring break hold off pressure

105 PSI (7.2 bar)

Port

Connection

Supply port, primary air

1/2” Push-to-Connect (PTC)

Supply port, secondary air

1/2” PTC

Delivery ports, 4 ports

3/8” NPTF

Primary brake control

1/2” PTC

Secondary brake control

3/8” PTC

Park brake control

3/8” PTC

5. Brakes Tractor Protection Valve Used on trucks intended to pull a trailer. Protects system air pressure on the towing vehicle in the event of a trailer breakaway. Make

Meritor Wabco


150 PSI (10.3 bar)

Port

Connection

Supply port, from hand control valve

3/8” Push-to-Connect (PTC)

Supply port, for primary brake control

1/2” PTC

Supply port, from secondary brake control

3/8” PTC

Supply port, trailer emergency air

3/8” PTC

Stop light switch signal

1/4” PTC

Delivery port, trailer service brakes

1/2” NPTF

Delivery port, trailer emergency air

1/2” NPTF

Air Governor Make

Meritor Wabco

Max. operating pressure

150 psi

Cut-in pressure

110 psi

Cut-out pressure

130 psi

All ports

1/8” NPTF

93

94

5. Brakes

Relay Valve and ABS Modulator Valves Assembly Rear brake control valving, can also include an additional solenoid valve in the assembly for traction Control function. Make

Meritor Wabco


150 PSI (10.3 bar)

Crack pressure

5.5 PSI (0.4 bar)

Port

Connection

Control port

1/4” NPTF

Supply port

1/2” NPTF


1/2” NPTF

Safety Valve Over pressurization protection mounted in the wet tank. Make

Meritor Wabco


150 PSI (10.3 ± 0.7 bar)

One Way Check Valves Located in the primary and secondary air reservoirs to protect against air loss, one in each air tank. Make

Norgren or Bendix depending on the air tank installed.

5. Brakes Pressure Protection Valve Manifold Frame mounted valve with multiple delivery ports. Purpose is to supply air to all non-brake related systems. Protects the main brake air by disallowing pressure loss in the main air system lower than 70 psi in the event of a non brake related system failure/leak. Port

Connection

Control port

Meritor Wabco

Supply port

150 psi (10.3 bar)

Opening pressure

85±10 psi (5.9±0.7 bar)

Closing pressure

67±7 psi (4.6±0.5 bar)

Port

Connection

Supply port

1/2” PTC


1/4” PTC


3/8” PTC

95

96

5. Brakes

Pneumatic Electric Interface Panel

W5001392

AP-TD

Application air pressure, transducer

2

REAR SUP

Rear air suspension, transducer

3

SLS

Stop light switch

4

FRT SUP

Front air suspension, transducer

5

PBS

Parking brake, switch

B-TD

“B” tank, transducer

PARK

Pneumatic connection/air line connection

A-TD

“A” tank transducer

9

B-Tank


10

A-Tank


1

6

7 8

11

Cab power supply (+ —)

6. Suspension and Steering

97

Specifications Wheel Alignment The following alignment specifications represent the industry standard established for a mid point target value on wheel alignment. Setting alignment for the target value minimizes inherent variations in measurement systems and provides optimum tire life. All values given in the table are for unladen vehicles with no trailer connected. Note: Actual measurement can vary and still meet factory specifications. Contact the original equipment manufacturer for specification questions. Steer Axle:

Toe-In ........................................................................

1.5 mm (1/16 in.) 0.08

Camber ......................................................................

Less than 1/4 (2)

Caster ........................................................................

+2.5 ± 1.0

Drive Axle:

Thrust angle (Square) ................................................

0.0

or 0 in.

Scrub (Parallelism)

0.0

or 0 in.

Lateral Offset

0 in.

Trailer Axles & Dollies:

Thrust angle (Square) ................................................

0.0

or 0 in.

Scrub (Parallelism)

0.0

or 0 in.

Lateral Offset

0 in.

NOTES:

1. All specifications are measured with vehicle in static, unladen condition. 2. Camber angle changes normally involve bending the axle beam, which may void the axle manufacturer’s warranty. If the measurement exceeds this value consult the vehicle, axle, and/or alignment equipment manufacturer.

98


Steering Steering Wheel/Adjustment, Steering Column

1

Clearance in steering wheel universal joints, lower steering column 1 ........................................................

Zero slack

Elasticity/slack in lower steering column, steering column in working position and turned with ± 10 Nm ..............

1.2

Elasticity/slack in lower steering column, steering column in working position and turned with ± 20 Nm ..............

1

Distance between locking device forks ........................

59 ± 1 mm (2.3 ± 0.03 in.)

Maximum distance between pedal upper bend - notch in pedal anchorage ..........................................................

5 mm (0.19 in.)

When the steering column is pulled out, outside the ordinary driving position, slack is permissible

Power Steering Gear Model

TRW TAS-65

Sheppard M100

TRW THP60

TRW TAS 85

Type

Ball nut

Ball nut

Ball nut

Ball nut

Ratio

18.4:1

18.9:1

18.2: 1

21.0:1

Steering wheel travel

4.5 turns

4.75 turns

4.75 turns

4.75 turns

Max. output torque

43,050 in-lb (@ 2175 psi)

43,050 in-lb (@ 2175 psi)

43,6000 in-lb (@2682 psi)

58,850 in-lb (@ 2175 psi)

6. Suspension and Steering Power Steering Pump Engine

VOLVO D12

Cummins CU15 (ISX)

Rotation

cw

cw

Drive type

gear

spline

Displacement /rev (cm3)

18 (VN) 18-25 (VHD)

22-25 (VN) 22-36 (VHD)

Oil type

Dexron II or Dexron III

Pressure output (max)

18.5 MPa (2683 psi)

Pressure output (min)

12.5 MPa (1800 psi)

Regulated Flow

16 liters/min (4.2 gpm)

System

VHD

VN

Oil capacity

4.7 liters (1.25 gal)

2.8 liters (0.74 gal)

99

100


Tightening Torques Steering Wheel Steering wheel center bolt

85 ± 15 Nm (63 ± 11 ft-lb)

Note: Steering wheel center bolt is not to be reused

Steering Column Upper steering column attachment bolts

15 ± 3.5 Nm (135 ± 30 in-lb)

Gas spring bolts

17 ± 3 Nm (150 ± 25 in-lb)

Steering Shaft Steering shaft U-joint pinch bolts

60 ± 10 Nm (45 ± 7 ft-lb)

Steering Gear Pitman arm retainer (Sheppard)

as marked on retainer

Pitman arm pinch bolt (TAS)

400 ± 60 Nm (295 ± 45 ft-lb)

Pitman arm jam nut (ZF)

600 ± 50 Nm (445 ± 37 ft-lb)

Mounting bolts, steering gear

540 ± 90 Nm (400 ± 67 ft-lb)

Pitman arm/drag link

200 ± 30 Nm (148 ± 22 ft-lb)

Power Steering Pump Housing bolts

45 ± 5 Nm (33 ± 4 ft-lb)

Mounting bolts

46 ± 1 Nm (34 ± 1 ft-lb)

7. Chassis, Springs, Damping, and Wheels

101

Specifications Suspension Location

Diameter

Grade

Torque

U-Bolts for Suspension VN Front Mechanical Suspension

M20

VN Front Air Suspension

M20

420 Nm (310 ft-lb)

VHD Front Suspension

M20

550 Nm (405 ft-lb)

VN, VHD Volvo T-Ride Rear Suspension (38,000 — 46,000 lbs.)

M16

200 Nm (150 ft-lb)

M20

500 Nm (370 ft-lb)

M20

350 Nm (260 ft-lb)

M24

600 Nm (445 ft-lb)

VN, VHD Volvo Multi-leaf Rear Suspension (4x2)

M22

500 Nm (370 ft-lb)

VN Volvo Rear Suspension (VOAS)

M20

500 Nm (370 ft-lb)

M24

575 Nm (425 ft-lb)

Radius Spring to Spring Hanger Bracket

M16

8.8

275 ± 45 NM (203 ± 33 ft-lb)

Air Spring Crossbeam (Pedestal) to Leaf

M12

10.9

105 ± 20 Nm (77 ± 15 ft-lb)

Air Spring to Crossbeam (Pedestal)

M12

8.8

50 ± 10 Nm (37 ± 7.5 ft-lb)

Torque Rod to Frame-Mounted Bracket

M16

10.9

320 ± 50 Nm (236 ± 37 ft-lb)

Torque Rod to Axle Housing

M16

10.9

320 ± 50 Nm (236 ± 37 ft-lb)

Shock Absorber Bracket to Frame

M14

10.9

200 ± 45 Nm (148 ± 33 ft-lb)

Shock Absorber to Bracket (Upper and Lower)

M16

8.8

275 ± 45 Nm (203 ± 33 ft-lb)

Bracket for Load Leveling Valve to Frame

M14

10.9

200 ± 45 Nm (148 ± 33 ft-lb)

VN, VHD Volvo T-Ride Rear Suspension (48,000 — 70,000 lbs.)

550 Nm (405 ft-lb)

102

7. Chassis, Springs, Damping, and Wheels Location

Diameter

Grade

Torque

Load Leveling Valve Control Arm to Lever on Valve and Air Bag Pedestal

M6

8.8

10 ± 1.5 Nm (7 ± 1 ft-lb)

Spring Hanger Bracket to Frame

M14

10.9

200 ± 45 Nm (148 ± 33 ft-lb)


103

Ride Height and Pinion Angle Specifications Frame Height, mm (in.)

Ride Height mm (in.)

Pinion Angle (Drive axle 1)


Meritor RT40-145

266 (10.47)

axle space 1320

220 ± 5 (8.7 ± 0.2)

2.5 ± 1

13.0 ± 1

RRH 200

axle space 1520

220 ± 5 (8.7 ± 0.2)

2.5 ± 1

11.5 ± 1

300 (11.81)

axle space 1320

203 ± 5 (8 ± 0.2)

2.5 ± 1

13.0 ± 1

RRH 180

axle space 1520

203 ± 5 (8 ± 0.2)

2.5 ± 1

11.5 ± 1

266 (10.47)

axle space 1320

180 ± 5 (7.1 ± 0.2)

2.5 ± 1

13.0 ± 1

RRH 160

axle space 1520

173 ± 5 (6.8 ± 0.2)

1.8 ± 1

12.2 ± 1

266 (10.47)

axle space 1320

220 ± 5 (8.7 ± 0.2)

2.5 ± 1

12.0 ± 1

RRH 200

axle space 1520

220 ± 5 (8.7 ± 0.2)

2.5 ± 1

10.5 ± 1

300 (11.81)

axle space 1320

203 ± 5 (8 ± 0.2)

2.5 ± 1

12.0 ± 1

RRH 180

axle space 1520

203 ± 5 (8 ± 0.2)

2.5 ± 1

10.5 ± 1

266 (10.47)

axle space 1320

163 ± 5 (6.4 ± 0.2)

1.8 ± 1

11.3 ± 1

RRH 160

axle space 1520

161 ± 5 (6.3 ± 0.2)

1.6 ± 1

11.1 ± 1

266

axle space 1320

220 ± 5 (8.7 ± 0.2)

2.5 ± 1

8.0 ± 1

RRH 200

axle space 1550

220 ± 5 (8.7 ± 0.2)

2.5 ± 1

2.5 ± 1

300

axle space 1320

203 ± 5 (8 ± 0.2)

2.5 ± 1

8.0 ± 1

RRH 180

axle space 1550

203 ± 5 (8 ± 0.2)

2.5 ± 1

2.5 ± 1

Dana 404

DST 40

Meritor MT40–14M

266

axle space 1350

220 ± 5 (8.7 ± 0.2)

2.5 ± 1

2.5 ± 1

RRH 200

axle space 1550

220 ± 5 (8.7 ± 0.2)

2.5 ± 1

2.5 ± 1

300

axle space 1350

203 ± 5 (8 ± 0.2)

2.5 ± 1

2.5 ± 1

RRH 180

axle space 1550

203 ± 5 (8 ± 0.2)

2.5 ± 1

2.5 ± 1

104


Frame Height, mm (in.)

Ride Height mm (in.)


220 ± 5 (8.7 ± 0.2)

3.5 ± 1


4X2 VOAS with any Axle

266 (10.47) RR H200

Table 1. Ride Height and Corresponding Pinion Angle as measured from the axle center to the frame rail bottom (unloaded). As measured from the axle center to the frame rail bottom. *In the event that both the ride height and pinion angles can not be adjusted at the same time for 6X4s, the ride height should be adjusted to the minimum cancellation error angle for the intermediate prop shaft, then lowered by 10 mm. Note: Working angles are measured at the forward axle joint or rear axle joint.


105

Suspension Applications Note: There are different vehicle suspension ride height (RRH) versions. RRH-180 and RRH-220 has a stamped sheet metal torque rod bracket with Meritor RT-40-145 axles. All other axles have cast iron torque rod brackets. RRH-160 has always had cast iron torque rod brackets. Suspension Configuration

Maximum GAWR Metric Ton (lb)

4x2

6x4

Axle Spacing mm (in.)

Required Number of Parking Chambers

9 (20,000)

N/A

TWO

17 (38,000)

1320 (52)

TWO (1st Axle)

1320 (52)

FOUR

1524 (60)

FOUR

18 (40,000) 18 (40,000)

Maximum GCW Metric Ton (lb)

50 (110,000) (1)

Available Axles

Models

Metric Ton (lb)

Eaton Meritor

10 (23,000)

Eaton Meritor

18 (40,000)

(1) GCW (Gross Combination Weight) rating can be reduced by vehicle operating applications, engine horsepower/torque, axle type/model, axle ratio, and/or vehicle tire size.

106


Wheels Drive Axle Shaft Nuts, Tightening Torque Fastener

Torque Values

Fastener

Torque Values

Thread Size (in.)

Lock Nut

Thread Size (in.)

Lock Nut

0.75 - 16

372 ± 34 Nm (275 ± 25 ft-lb)

M14 x 2

150 ± 15 Nm (110 ± 10 ft-lb)

Fastener

Torque Values

Thread Size (in.)

Lock Nut

5/8

135 ± 20 Nm (100 ± 15 ft-lb)


Wheel Nuts, Tightening Torque

W7000774

Tightening sequence

All disc wheels for the VN and VHD-series have nuts that require torque of 610 Nm (450 ft-lb). For dual wheels, the following procedure must be used. 1

Loosen nuts.

2

Tighten nuts to a torque of 610 Nm (450 ft-lb)

For stud and hub piloted wheel nuts: 610 — 678 Nm (450 — 500 ft-lb) For spoke wheels, check the manufacturer’s specifications.

107

108

8. Body, Cab, and Interior Trim

Specifications Cab Designations • • • • •

VNL 780 VNL 670 VNL 630 VNL 430 VNL 300 (Daycab)

• • • • •

VNM 630 VNM 430 VNM 200 (Daycab) VHD 200B (Axle Back) VHD 200F (Axle Forward)

L=long hood, M=medium hood

W8003128

8. Body, Cab, and Interior Trim Seats Tightening Torques Driver’s Seat, Anchorage Tightening torque, seat bracket .........................

48 ± 8 Nm (35 ± 5.9 ft-lb)

Safety Belts and Bunk Restraints Safety belt D-ring, National and Isringhausen seats ...........................................................

50 ± 7 Nm (37 ± 5 ft-lb)

Retractor, National and Isringhausen seats ..

50 ± 7 Nm (37 ± 5 ft-lb)

ICP bar, National seats ................................

67 ± 7 Nm (50 ± 5 ft-lb)

Seat belt (seat frame), Isringhausen seat ......

50 ± 7 Nm (37 ± 5 ft-lb)

Bunk restraints, 7/16 in. screw ....................

68 ± 7 Nm (50 ± 5 ft-lb)

Bunk restraints, M8 screw ..........................

24 ± 4 Nm (18 ± 3 ft-lb)

109

110

8. Body, Cab, and Interior Trim

Climate Control Unit Specifications General Refrigerant, type .......................................

R134a (Tetraflourethane)

Air conditioning, volume .........................

1400 g - day cabs 1600 g - VN 430, 630 1700 g - VN 670, 780

Compressor, marking ...............................

SD 7H15

No. of cylinders ........................................

7

Cylinder volume .......................................

155 cm³ (9.5 in³)

Compressor coupling ............................... Electromagnetic Lubricating oil capacity ...........................

300 cc (10.14 oz)

Pressure Monitor Switch Points Note: Since the pressure transducer is downstream of the compressor, gauge readings could be .5 bar (7.3 psi) to 1.5 bar (21.8 psi) higher if the gauge is used at the compressor discharge. High pressure

opens at .............................................

24 ± 2 bar (348 psi)

closes at .............................................

20 ± 2 bar (290 psi)

Low pressure

opens at .............................................

2.0 ± 0.2 bar (29 psi)

closes at .............................................

2.1 ± 0.2 bar (30 psi)

Volvo Trucks North America, Inc. P.O. Box 26115 Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www.volvotrucks.volvo.com

PV776-20 003739 () 11.2004 © Volvo Trucks North America, Inc. , 2004

PV776-20 003739

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