Training Tips & Tactics: Module 1-Foundation

TRAINING TIPS & Module 1- foundation
TACTICS
1
2
Contents
Brand image
Core values
Impact
Safe working practices
Service and Inspection
3
4
Introduction
About this This guide is intended as a memory jogger for the
Pocket-guide knowledge you have gained during your training course.
The guide includes a summary of the material covered in:
Module 1 - of the Volvo Truck Technical Training Plan.
Use IMPACT This guide is not intended as a substitute for the Service
Information contained in IMPACT.
Before starting any repair, it is essential that you get the
latest up to date information for the job you are going to
do from IMPACT
5
Danger, Warning, In this guide, risk of injury or damage is indicated by the
Caution & Note following headings:
DANGER - indicates a risk of serious personal injury or

death.
WARNING - indicates risk of personal injury, or severe

product damage.
CAUTION - indicates risk of product damage.
Note - draws attention to special methods or particular

features.
Pay attention to Read and implement all DANGER, WARNING and

these headings CAUTION instructions.
6
Replacement When replacement parts are required, it is essential that
parts only Volvo genuine parts are fitted. If Volvo genuine parts
are not used:
- safety features embodied in the vehicle or components

may be impaired.
- performance and/or operation of the vehicle or

components may be adversely affected
- Volvo warranty terms may be invalidated.
7
Specification Volvo are constantly seeking ways to improve their
products, and alterations take place accordingly.
Whilst every effort has been made to ensure the
accuracy of this guide, it should not be regarded as an
infallible guide to current specifications of any
particular product.
Neither Volvo, nor the supplier of this book shall, in any
circumstances, be held liable for inaccuracy or the
consequences thereof.
Copyright All rights reserved. No part of this publication may be

reproduced, stored in a retrieval system, transmitted or
copied without written permission from Volvo Truck &
Bus Ltd.
c Volvo Truck & Bus Ltd 2004
8
Brand image
9
Brand image
10
Brand image
Company asset Brand image is an extremely important and valuable asset

for any company. Brand image includes such things as -
the company name, how that name is styled and presented
- the ‘logostyle’ - the design, layout and color scheme of
dealer premises, and company vehicle livery.
Brand image is also about what the company stands for,

and how it is perceived by the outside world.
The Volvo brand image is firmly established and

Quality & Safety recognized throughout the world, and is synonymous with
quality and safety, two of the ‘core values’ of the company.
Display rules Volvo applies strict rules on display and presentation of the
brand image - in particular the logostyle.
11
Brand image
Promote the It is in the interest of all representatives of the company -

image including you! to promote and reinforce our brand image at
every opportunity.
Your contribution You can make your contribution in many ways; here are
just a few:
- be courteous with your customers and colleagues
- work with care and do a quality job
- work with safety in mind - your own and those
around you
- keep your work place clean and tidy
12
Impact
Core values
13
Core values
Quality Quality work is a fundamental part of all activities,

including:
♦ design development and production. An enormous

amount of energy and expense is committed to ensure that
a quality product leaves the factory - that’s why customers
buy them.
♦ sales and service. As a valuable member of the ‘service’

team, one of your tasks is to ensure that quality is
maintained throughout the life of the vehicle.
How ? - by doing quality maintenance and repair work.
Focus on
customers Keep your focus on your customers - they pay your wages !
14
Core values
Safety Safety applies to:
♦ the product - must be safe to drive and operate. Volvo

are world leaders and innovators of features which make
the product safer for the driver and for others.
♦ the work place - the factory and your workshop. Working

methods must be driven by safe practices and care for
others.
♦ the global view. Volvo takes a worldwide view for the

guidelines on the commitment to safety.
15
Core values
Recycle mark
16
Core values
Concern for the Volvo’s concern for our environment takes in the whole
environment picture - an ‘Holistic’ view. This includes the effects of:
♦ making the products. The efficient use and selection of

natural resources for the production process, and for
materials used in that process.
♦ using the products - e.g. fuel economy and exhaust

emissions. Volvo’s extensive research and use of
advanced technology minimizes these effects.
♦ recycling whenever possible, or safe and efficient

disposal of components at the end of their working life.
Volvo products contain many components made from
recyclable materials - ‘recycling’ marks appear on these
components.
17
18
Impact
19
Impact
20
Impact
On-line resource Impact is the on-line resource centre for Volvo Truck and
centre Bus service information.
It contains Service Manuals, bulletins and Parts Catalogues
dating back to 1987.
Data is held on a computer at Volvo HQ in Sweden, and is

constantly updated.
In case of a system failure, Impact is also published on a

DVD.
However, to ensure that you are reading the latest
information, the on-line system must always be your first
choice.
21
open a new job card Help
open an existing job card
abbreviations
navigator for bulletins and

info.
sniffer dog to search for

info.
navigator for service

manual and parts
catalogue 22
The main icons Note: Icons become active/inactive dependent on which
screen you are using
23
Impact
IMPACT Logon
User ID:
Password:
Application Language Britsh English
24
Impact
Note - Citrix ICA client, & Uniprint must be installed.
- if Impact is left inactive for 1 hour, the system will

automatically log-off.
Log on to Impact - enter Impact web-site address:

http://impact.vee.volvo.se/
OR
- enter via dealer violin homepage - training- impact.
- ensure ‘Application Language’ is set to British English.
- enter your User ID & Password.
25
Impact
IMPACT Training 1
File Information Job Card Note Log Help
Displays last 20 places visited

Other in the session - cleared after
log-off
Personal/public notes can be

added - e.g. part line/number
notes, service information
notes
Displays latest updates -

remains for 6 weeks
Other useful
menu Click on menu item to open ‘drop-down’ menus.
information 26
Impact
Searching for By making the right selections you can search for either
information ‘Parts’ or “Service’ information.
The search basic rules are the same, but the displays differ
slightly.
Chassis You can search with or without a chassis number.

number ? If you know the chassis number, and search using the
number, the system will display only the material applicable
to that vehicle.
Example In the example search which follows, we will search for

‘Fuel filter - engine’.
27
Impact
IMPACT Training 1
1
Function Group Model FH12
233
2
Information Type Parts 3 Parts
All Fuel filter, engine

0 General
1 Service and maintenance
> 2334, 04, FH12, TB-7632157 6 7
2 Engine, engine mounting and equipment
> 20 General
> 21 Engine
> 22 Lubricating and oil system
> 23 Fuel system
>> 230 General
>> 232 Air cleaner and shutter housing
>> 233 Fuel pump and filter
4
Retrieval 5 Show 8
28
Impact
PARTS: LH window:
Searching for 1 Click on Navigator.
information - 2 Enter the model type
chassis number
NOT known 3 In ‘Information type’ select ‘Parts’
4 Scroll down the menu until the item you want information
on is highlighted - 2 Engine > 23 Fuel system >> 233 Fuel
pump and filter.
5 Press ‘Retrieval’ button.
RH window:
6 Open ‘Fuel filter- engine’ folder.
7 Select vehicle/engine type and specification.
8 Press ‘Show’ button - parts information now appears.
29
Impact
IMPACT Training 1
1
Function Group Model FH12
233
2
Information Type All Service Information 3 All Service Information
All
0 General
23303-2 Fuel filter, replace (one)
> -FH12, D12C340
6
1 Service and maintenance > -FH12, D12C380
2 Engine, engine mounting and equipment > -FH12, D12C420
> 20 General > -FH12, D12C346 7
> 21 Engine
> 23 Fuel system
>> 230 General
4
Retrieval 5 Show 8
30
Impact
SERVICE: LH window:
Searching for 1 Click on Navigator.
information - 2 Enter the model type
chassis number
3 In ‘Information type’ select ‘All Service Information’
NOT known
4 Scroll down the menu until the item you want information
on is highlighted - 2 Engine > 23 Fuel system >> 233 Fuel
pump and filter.
RH window:
6 Open ‘Fuel filter- replace’ folder.
7 Select vehicle/engine type and specification.
8 Press ‘Show’ button - repair information now appears.
31
Impact
IMPACT Training 1
6 1
Job Card 55
2 Reception Vehicle Service and Parts 5

Customer Information Vehicle Information
A 560061 3
Chassis ID:
Registration No. KX03AAE 4
Country
Fleet No.
Model FH12
Mileage
32
Impact
PARTS: 1 Open a new job card.
Searching for
2 Select ‘Reception’ tab.
information -
chassis number 3 Enter ‘A’ and the chassis number.
KNOWN 4 Select ‘tick’ box.
5 Select ‘Vehicle’ tab for vehicle information.
6 Keeping the job card open, select navigator.
33
Impact
IMPACT Training 1
Function Group 233 Model FH12
Information Type Parts 7 Parts
All - accelerator linkage

0 General - cooling system
1 Service and maintenance - engine
2 Engine, engine mounting and equipment - fuel system
9
Retrieval 8 Show
34
Impact
7 In information type, select ‘Parts’.

8 Press ‘Retrieval’ button - sub sections now appear in the
RH window.
9 Select ‘fuel system’.
35
Impact
IMPACT Training 1
FH12 , 23, Parts< FH12 CHID
Parts
- accelerator linkage
- cooling system
Description Notes - engine
fuel pump - fuel system
water separator
fuel filter
11
12
Retrieval Show 10
36
10 Press ‘Show’ button - a new window now appears.
11 Select part required - ‘fuel filter’.
12 Press ‘Go to’ button - parts information now appears.
37
Impact
IMPACT Training 1
6 1
Job Card 55
2 Reception Vehicle Service and Parts 5

Customer Information Vehicle Information
A 560061 3
Chassis ID:
Registration No. KX03AAE 4
Country
Fleet No.
Model FH12
Mileage
38
Impact
SERVICE: 1 Open a new job card.
Searching for
2 Select ‘Reception’ tab.
information -
chassis number 3 Enter ‘A’ and the chassis number.
KNOWN 4 Select ‘tick’ box.
5 Select ‘Vehicle’ tab.
6 Keeping the job card open, select navigator.
39
Impact
IMPACT Training 1
Function Group 233 Model FH12
Information Type All Service Information 7 All Service Information
All
0 General - 23302-2 Feed pump. replace (Repair 2331)
1 Service and maintenance
2 Engine, engine mounting and equipment > 23306-3 Fuel filter, replace (one) (repair 2335)
> 20 General
>> FH12, D12D240
> 21 Engine 10
> 23 Fuel system
>> FH12, D12D420 11
>> 230 General
8
Retrieval 9 Show 12
40
Impact
7 In ‘Information type’ select ‘All Service Information’
8 Scroll down the LH menu until the item you want
information on is highlighted - 2 Engine > 23 Fuel system
>> 233 Fuel pump and filter.
RH window:
10 Open folder - ‘23306-3 Fuel filter, replace (one)’
11 Select model/engine
12 Press ‘Show’ button - repair information now appears.
41
42
Safe Working Practices
43
44
The adoption of safe working practices - at all times - is
essential for health and well-being.
Carelessness, or the use of unsafe and unspecified

methods and equipment can endanger your health and
your life and, quite possibly, the health and life of others
around you.
Down to you Safe working is largely down to you.
Service information can give you the safe methods and

procedures developed and approved by Volvo, and it can
flag-up particular hazards.
Common sense What it cannot do is put into gear your own common sense,
or instill the need to care and think about what you are
doing at all times.
45
46
Your Legal
Responsibility You have a legal responsibility to ensure that:
Safe working ♦ you work in a safe and careful manner at all times.
Amongst other things, this means - following the Volvo
specified repair procedures and using Volvo specified
equipment.
The right gear ♦ you use the Volvo, or dealer, specified safety clothing
and equipment. The specified clothing and equipment is
likely to differ from job to job.
Make sure you use the right gear at the right time every
time.
Health & safety ♦ you understand the Health and Safety Policy and Rules
rules in your working environment.
47
48
Personal The following protective items must be worn when needed -
protection typical cases are suggested:
♦ safety boots with steel toe caps - all the time.
♦ overalls - all the time.
♦ eye protection goggles - when welding, grinding/cutting/

drilling, working with batteries.
♦ latex gloves - most of the time - especially dealing with

lubricants and fluids, when not wearing other gloves.
♦cloth gloves - for general handling, when working with:

hot objects, sharp objects, wire rope.
49
50
Personal ♦ ear defenders - when using, or working near, any noisy

Protection - cont. equipment e.g. when grinding/cutting/drilling.
51
12 volt
+ 24 volt _
+
_
+
12 volt
_
Two batteries connected in series
Negative earth
52
Batteries Because of the stored electrical energy and electrolyte they
contain, batteries are a special case for safe working. The
following are the main points to note:
- All Volvo trucks and buses have two 12 volt batteries

linked together in series, with negative earth.
Series connection means 24 volts is supplied to the
electrical system.
- Each battery stores up to 190 amps, which represents a

great deal of electrical energy.
- Battery electrolyte is a mixture of water and sulphuric

acid, which is highly corrosive and will cause severe burns
on contact.
- When batteries are being charged hydrogen and oxygen

is produced, and this mixture is highly explosive.
53
54
Batteries - cont. When handling batteries always:
- wear gloves, goggles and overalls.
- ensure that metal tools do not touch both terminals, or a

terminal and bodywork, at the same time. The resulting
sparks will cause severe burns, damage or fire.
- disconnect the negative cable first, connect positive cable

first.
55
Lubricants and
fluids
56
Lubricants and Many different fluids and lubricants are used in vehicles.
fluids These are the main ones:
- engine oil
- manual/auto transmission oil
- axle/differential oil-
- PAS oil (ATF)
- general purpose grease
- antifreeze
- clutch/brake fluid
- diesel fuel
Harmful Most of these are poisonous and harmful to skin, and some
can cause cancer.
Corrosive Clutch/brake fluid is corrosive and will damage paintwork.
57
Lubricants and
fluids
58
Lubricants and
fluids - cont.
Precautions - drain oils and fluids into suitable containers, and dispose
of safely in accordance with company policy. Clean up
spillage.
- do not mix different makes/types of oils and fluids. Certain

combinations can be dangerous and may cause damage.
- follow makers instructions for the use of products such as

- adhesive, sealer, release agents etc.
59
Lifting equipment
60
Lifting The main items of lifting equipment you will use are:
equipment
- trolley jacks, bottle jacks - almost always used with
wooden blocks, and always used with chassis stands and
wheel chocks.
- vehicle lifts or ramps.
- cranes and hoists.
Safe Working All lifting equipment has a ‘safe working load’ (SWL), which
Load is the greatest weight the equipment can safely support.
Your company must ensure - by law - that all such
equipment is regularly tested for SWL and safety.
61
62
Lifting
equipment -
cont.
Precautions - - ensure that the vehicle and the lifting equipment are on
general firm level ground.
- ensure that the SWL of the lifting equipment - including

chassis stands - is adequate for the load. The vehicle
weight is on a plate inside the driver’s door.
- before use, check equipment for damage/cracks/ signs of

stress.
63
64
Lifting equipment
- cont.
Precautions - - select a safe location for the head of the jack and chassis
jacking stands
Examples are: chassis frame side/cross members, axles,
hubs.
CAUTION: Do not position a jack or stand under single leaf

taper springs. If the surface is damaged stress points will
develop.
- select wheel chocks which are big enough to prevent

tyres rolling over them. Before lifting, position wheel chocks
at the front and rear of tyres which will stay on the ground.
65
66
! WARNING ! On vehicles with air suspension, air leaks, disconnection of
Air air pipes, or inadvertent switch operation etc. can cause a
suspension sudden change in chassis frame to axle distance.
To prevent any change, put wooden blocks between the
frame and axles.
Jacking 1 Chock wheels.

procedure 2 Position jack under safe point. If necessary, to ensure
secure fit or to prevent damage, put a wooden block
between jack head and jacking point.
3 Operate jack and raise vehicle to required/sensible
height.
4 Position chassis stand(s) under safe point.
5 Lower vehicle until ALL weight is off the jack and on the
stand(s).
6 Check stand security and stability.
7 Remove jack. 67
68
Cab tilt
procedure
Precautions - - ensure that there is enough space above and in front of

general the vehicle to accommodate the tilted cab.
- ensure that people are kept away from the tilt area.
- ensure that there are no loose items in the cab which may
fall during tilting and cause damage.
! WARNING ! All wheels must be fitted and on the ground.

If all wheels are not fitted, the weight of the tilted cab may
overturn the vehicle.
69
70
Cab tilt procedure 1 Ensure that the park brake is on and neutral is selected.
Electric tilt 2 Turn the starter switch to ‘radio’ position.

3 Turn the cab tilt switch to ON position.
Manual tilt CAUTION

Use ONLY the Volvo supplied bar and socket.
Other tools may not fit correctly on the pump hexagon,
leading to a risk of damage or injury.
4 Remove the cab tilt bar from the side locker, and fit it to
the pump.
5 Turn the pump switch to ‘tilt cab’.
6 Operate the pump with the bar.
All models 7 Ensure that the cab tilts as far as possible, and stops.
71
72
73
74
Service & Inspection
What does Service means many things but, in this particular instance,
‘Service’ mean ? service means:
Planned work - pre-planned ‘maintenance’ work, done at specific

intervals.
Note that this statement excludes ‘repair’ work, which is the

work necessary to correct a fault or damage. (Except for
minor component changes, such as bulbs, or routine
adjustments).
Unplanned work Such work is unpredictable and, therefore, unplanned.
75
Advantages of - unplanned repairs and breakdowns are minimized. This

pre-planned means less disruption, less inconvenience, and less cost
services for the owner.
- the vehicle is kept in a good condition, which means it is:

safe, reliable, fuel efficient and legal.
It is also more likely to pass the annual MOT with no
problem, and it keeps running longer.
- for the dealer network, pre-planned service work

simplifies workshop planning and job assignment.
Also, providing that you do a good job in the allotted time,
the work is a big money earner.
Good for the dealer - and you !
76
Disadvantages of - careless, incorrect or incomplete servicing can cause

pre-planned other problems, and may result in unplanned repairs.
services
- those unplanned repairs may have to be paid for by the
dealer - your employer.
Not good for them - or you !
77
Types of service To be able to offer efficient and economic service

plans to suit the needs of many different operating
environments, eleven service types have been
developed:
- Intermediate Service
- Lubrication only
- Basic Service
A, B
- Major Service
A, B, C, D, E, F, G
78
Which Type of With so many operating conditions and eleven different

Service - and possible services, it’s important to keep track of the history
when ? to be able to plan future servicing patterns.
Volvo Service Fortunately, Volvo has developed an automated service

Program planning program.
When the details of a vehicle, and it’s operating conditions,

are first entered, the program automatically works out a
service planning matrix.
When a service is due, the correct service sheet is
generated.
79
Volvo PM Service Inspection Protocol 1.2 Volvo Trucks
Dealer ABC Truck & Bus Date 19/03/04
Customer Commercial United RO No. WAR 1200AM

Model Select FM12
Address 123 Road Reg. No. T100 ABC

Engine Select D12D
Town XYZ Kms 30,000
County Warwickshire Country ENGLAND
Intermediate Service
Customer & vehicle details

80
Service sheets Service sheets can be divided into five main areas. The
first area is at the top of the sheet.
1 Customer If the vehicle details are in VOSP, all the details will be
and vehicle printed out - except current mileage.
details
Completion is It is important that these details are correctly entered to

important ensure:
- records are correct and up to date.
- the correct VST’s are applied.
- warranty claims are not rejected.
- invoices are correct.
- a professional approach is apparent.
81
Judgement codes ( ) Serviceable - (S) Safety related repair required - (R) General repair recommended - (O) Observe condition or performance
Manual No.
Check number
Testers
Check & Report on Function Condition &
Security of the items below
General round vehicle & inside cab checks
1 Fault codes
2 W/sceen wipers, washers incl. h/lamps (25)
3 Electrical wiring & Equipment (42)

4 Instrument illumination
5 Ventilation, defroster, AC & Heaters
6 Audible Warning (Horn) (27)
7 Seat & Seat Belts (18/3)
82
2 The inspection All the checks to be done at this service are listed and
numbered.
Function Group Details of how the checks should be carried out are located
17 in Function Group 17.
MOT Testers If a reference number appears in the column ‘Testers

Manual Manual No.’ the check is part of the annual MOT.
The number cross-refers to the appropriate section in the
Testers Manual, where additional information will be found.
83
84
Judgement codes ALL ‘Judgement code’ boxes must be marked with the
appropriate code:
X = Serviceable, no fault found.

S = Safety related defect e.g. it would fail an MOT, or it is
illegal.
R = Repair recommended e.g. it is outside Volvo tolerance.
O = Observed worn/damaged, but still within Volvo
tolerance.
3 Lubrication Details of how lubrication should be carried out, and

lubricant and fluid specifications, are located in Function
Group17.
85
86
4 Measuring The Service sheet has boxes for recording the following
measurements:
- wheel nut torque.
- tyre tread depth and tyre pressure.
- brake lining thickness, lever travel and brake performance

test results.
- clutch wear.
Measuring To ensure accurate results, it is essential that all measuring

equipment equipment is in good condition, and accurately calibrated.
87
4 Measuring
- tyres 37. Tyre Depth (7/8) O/S
N/S
37. Tyre Pressure

(7/8) O/S
N/S
88
4 Measuring Boxes are provided to record the tread depth and tyre
- tyres pressure of 8 rear tyres and 4 front tyres - i.e. an 8 x 4.
For a 4 x 2, front boxes and 4 rear boxes should be used.
89
4 Measuring
- brakes
78. Brake test overall result (71, 72, 73)
Service (71) Sec (72) Park (73)
50%
Service Brake -
footbrake
90
4 Measuring
Note: If brake performance figures are not entered on the
- brakes
Service sheet, the vehicle cannot be considered
roadworthy.
GVW axle Record the GVW axle weights from the chassis plate inside
weights the driver’s door i.e. NSF, OSF, NSR, OSR.
Service brake Minimum acceptable values are:

test
(footbrake) - Vehicle 50% Gross vehicle Weight (38 - 44 tonne)
- Semi-trailer 45%
- Drawbar 45 %
91
4 Measuring
- brakes
20
4
10 2 30
6
0000 kg
00 %
0 Brake force 8
x 100 kg
0 40
Print Another
Test Report ? (Y/N)
92
4 Measuring
- brakes
Brake
efficiency Efficiency = total axle weights kg/GVW kg x 100.
Example What is the efficiency if GVW is 28000 kg?
Total axle weights: NSF 2000kg + OSF 2000 kg +

NSR 5000 kg + OSR 5000 kg = 14000 kg
14000/28000 = 0.5
0.5 x 100 = 50%
93
4 Measuring
- brakes
25%
Secondary
Brake
94
4 Measuring
- brakes
Secondary The secondary brake test will vary depending on the type
brake test of vehicle.
Generally the secondary brake is applied using the first
stage operation of the park brake control valve, this will
apply the spring brakes on all axles where spring brakes
are fitted. The efficiency of the secondary brake should be
25% of GVW (this is calculated in exactly the same way as
the service brake).
On FL6, which has a single function park brake control, the

secondary brake can not be applied independently.
Therefore the efficiency is calculated from the individual
performance of the service brakes on the front and drive
axle, each must produce an efficiency of at least 25%
95
4 Measuring
- brakes
16%
Park Brake
96
4 Measuring
- brakes
Park brake Minimum acceptable values are:
test
- 16% of GVW
- 12% Gross Train Weight (GTW) if type approval

certificate.
97
2 3
1
(9988698)
< >
X2
X1
X2
98
4 Measuring Note: On IShift transmissions there is no hole in the bell
- clutch housing. VCADS Pro Clutch Test 40010-2 must be used for
IShift.
Non - IShift 1. Insert tool (1) into the hole in the bell housing, with guide
flange (2) held against the housing.
2. Push bar (3) through the guide until it contacts the clutch
release fork.
3. Holding the bar and guide together, so that their relative

positions cannot change, remove the tool.
4. Measure distance X2.
99
SB411 - 18 X1 X2 Y D
SB411 - 20
100 mm 105 mm 5 mm 14/010/03
100 mm 1 137 mm 37 mm 14/010/04
100 mm 2
mm 3
X1 = measurement - new plate Clutch record label - Example only

X2 = measurement - plate with wear
Y (wear) = X2 - X1
Y max. single disc = 34 mm. Y max. double disc = 36 mm.
100
4 Measuring 5. Write the measurement under X2.
- clutch
6. Compare with measurement for a new plate under X1.
7. Write wear value under Y.
8. Write date under D.
101
5 Recording
defects
Volvo PM Service Inspection Protocol 1.2 Volvo Trucks
Defect Report Sheet

Confirmed Defect Description
Judgement Code
Standard Times
Number
The following should be carried out

(subject to Judgement Codes) Repair Description Completed Initials
Number
18 S NS Headlamp inop Renew bulb 3513 DS
102
5 Recording A ‘Defect Report Sheet’ is provided to log details of defects
defects noted on the Service Sheet.
All noted defects must be logged, and must match

comments on the Service Sheet.
Exceptions to If you are unable to do any of the checks - e.g. if the brake
signing the tester is not working, so that the brake test cannot be done,
declarations there is no way of knowing if the vehicle is safe and
roadworthy.
In such cases neither declaration can be signed.
Disclaimer If you find a defect, but the customer wants to do the repair
himself, you must ensure that Service Reception are aware
of this, and that the customer provides a written disclaimer.
In such cases the ‘rectification’ declaration cannot be
signed. 103
6 Signatures
Declaration (Inspection)
We certify that this vehicle has been inspected and serviced in

accordance with Volvo’s current recommendations and DoT vehicle
Inspectorate Testers Manual and that all applicable items have been
checked and found serviceable except as noted on the defect sheet.
Signature .........................................................................Technician
Print Name .......................................................................Technician
Checked by ........................................................ Supervisor/Manager
Print name ..........................................................Supervisor/Manager

104
6 Signatures
Declaration (Rectification - as noted on Defect Sheet)
I certify that codes S R defects have been rectified as initialled

on the Defect Sheet.
Signature .........................................................................Technician
Print Name .......................................................................Technician
I certify that the Service indicated above has been completed &
codes S R defects have been rectified and that in my opinion the
vehicle is in a safe and roadworthy condition.
Signature ........................................................ Supervisor/Manager
Print name ..........................................................Supervisor/Manager

NB Declaration must not be signed if S code defects are not rectified
105
Manual No.
Testers
Check & Report on Function Condition &
Security of the items below
General round vehicle & inside cab checks
1 Fault codes
Cross reference
2 W/sceen wipers, washers incl. h/lamps (25)
from Service
Sheet to 3 Electrical wiring & Equipment (42)
Vehicle
Inspection 4 Instrument illumination
Manual 5 Ventilation, defroster, AC & Heaters
6 Audible Warning (Horn) (27)
7 Seat & Seat Belts (18/3)
106
Vehicle
Inspection
Heavy Goods Vehicle Inspection Manual
Windscreen wipers and washers
Application
25
Manual -
example This inspection applies to all vehicles except those with an opening
windscreen or where an adequate view can be obtained by some other
only
means.
Procedure and Standards

Check the operation of the wipers and washers.
Wipers must be able to clear an adequate area of the screen to give the
driver a view of the road to the front and in front of both sides of the
vehicle.
Reasons for failure

1 Switches missing or defective.
2 Wipers: a. do not move over an adequate area - b. do not work
continually when switched on - c. blade missing, insecure, or so
deteriorated that it cannot clear screen effectively.
3 Washers: ineffective.
107
108
Service So that you use your time to best effect, and are able to
Process meet VST for services, it is essential that you carry out the
complete service process in a logical and efficient manner.
The following sequence is recommended:
1 Check job description on job card.

2 Inspection.
3 Inform service reception about any major faults.
4 Lubrication.
5 Brake test.
6 Test drive.
7 After test drive checks.
8 Clean vehicle and report completion to service reception.
109
Start
110
Inspection Note: If any faults are found during the inspection, make a
Procedure note of them on the service defect sheet.
1 Inside cab - check numbers 1 - 12.

2 Starting at driver’s door, work round the vehicle - check
numbers 13 - 45.
3 Tilt cab - observe safety precautions.
4 At ground level, inspect engine area, underside of cab
and cab exterior - check numbers 46 - 77
5 Go under vehicle.
6 Mentally divide the vehicle into sections. Starting at the
front inspect each section - check numbers 31 - 77.
7 Report any major defects to Service Reception.
8 Carry out lubrication procedure.
111
Lubrication
Procedure Note: Refer to the correct lubrication chart for lubricant
specifications, and locations.
At each grease point look for movement of old grease
around the joint. Movement indicates that new grease has
entered the joint.
Under the vehicle:
Starting at the front and working towards the rear, lubricate
all points shown on the chart.
Ground level:
Starting at the rear and working towards the front, lubricate
all points shown on the chart - including trailer coupling,
cab pivots/hinges.
Under cab:
Tilt cab - observe safety precautions.
Starting at the rear of the engine and working towards the
front, lubricate all points shown on the chart
112
Lubrication Oil and filters
Procedure Under the vehicle:
Drain oil - engine, gearbox, differential, other components.
Renew filters - engine oil, fuel.
Under cab:
Tilt cab - observe safety precautions.
Renew any filters not reached from below - engine oil, fuel.
Bleed the fuel system.
113
Job Card
Customer Vehicle Reg. Chassis No. Mileage
RO Number Technician
Description Time
114
Completing the What is written on the job card is very important.
Job Card Cost/warranty/ invoice staff get information from the card to
pass on to the customer, and to issue invoices.
To ensure that other people can understand the checks and

work that you have done, your writing style is important.
Two hints to - A, B, C Your style should be: Accurate - Brief -

remember Concise - compare the examples.
- Three C’s - Complaint - Cause - Corrective action
Complaint What is the customer’s complaint or problem ?
Example OK Customer complained that the head lights were faulty

115
Cause Understand the cause - what’s wrong ?
First, confirm for yourself that the headlights are faulty, then
find the cause of the fault.
Example OK Found headlights faulty due to chafing in wiring harness

which caused fuse and bulb to blow.
Example not Went to get keys from reception, then went out to the yard
OK to bring vehicle in. Geoff operated the stalk in the cab while
I checked the lights outside. Then I found that the bulbs did
not work so I replaced the bulbs.
The bulbs still did not work so I went to my tool box for a
multimeter to check for 24 volts ....................
116
Corrective Repair the fault, then ensure that the headlights now work
action correctly.
Example OK Repaired wiring harness, and replaced fuse and bulb.

Lights now operate to correct specification.
Example not I went to the parts store to get a wire joint sleeve. Then I
OK went to my tool box to get some wire crimps. I cleaned the
broken wire, then repaired it with the joint sleeve. Then I
went to the parts store for a fuse and bulb.
Then I replaced the fuse and bulb ...............
117
Notes
118
Notes
119
Notes
120
Notes
121
Notes
122
123
124

Training Tips & Tactics: Module 1-Foundation

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TRAINING TIPS & Module 1- foundation

Safe working practices

Service and Inspection

The guide includes a summary of the material covered in:

Module 1 - of the Volvo Truck Technical Training Plan.

DANGER - indicates a risk of serious personal injury or

WARNING - indicates risk of personal injury, or severe

CAUTION - indicates risk of product damage.

Note - draws attention to special methods or particular

Pay attention to Read and implement all DANGER, WARNING and

- safety features embodied in the vehicle or components

- performance and/or operation of the vehicle or

- Volvo warranty terms may be invalidated.

Copyright All rights reserved. No part of this publication may be

c Volvo Truck & Bus Ltd 2004

Company asset Brand image is an extremely important and valuable asset

Brand image is also about what the company stands for,

The Volvo brand image is firmly established and

Promote the It is in the interest of all representatives of the company -

Quality Quality work is a fundamental part of all activities,

♦ design development and production. An enormous

♦ sales and service. As a valuable member of the ‘service’

Safety Safety applies to:

♦ the product - must be safe to drive and operate. Volvo

♦ the work place - the factory and your workshop. Working

♦ the global view. Volvo takes a worldwide view for the

♦ making the products. The efficient use and selection of

♦ using the products - e.g. fuel economy and exhaust

♦ recycling whenever possible, or safe and efficient

Data is held on a computer at Volvo HQ in Sweden, and is

In case of a system failure, Impact is also published on a

open an existing job card

navigator for bulletins and

sniffer dog to search for

navigator for service

Application Language Britsh English

Note - Citrix ICA client, & Uniprint must be installed.

- if Impact is left inactive for 1 hour, the system will

Log on to Impact - enter Impact web-site address:

- ensure ‘Application Language’ is set to British English.

- enter your User ID & Password.

Displays last 20 places visited

Personal/public notes can be

Displays latest updates -

Chassis You can search with or without a chassis number.

Example In the example search which follows, we will search for

All Fuel filter, engine

2 Reception Vehicle Service and Parts 5

Function Group 233 Model FH12

Information Type Parts 7 Parts

All - accelerator linkage

7 In information type, select ‘Parts’.

FH12 , 23, Parts< FH12 CHID

2 Reception Vehicle Service and Parts 5

Function Group 233 Model FH12

Information Type All Service Information 7 All Service Information

Carelessness, or the use of unsafe and unspecified

Down to you Safe working is largely down to you.

Service information can give you the safe methods and

♦ safety boots with steel toe caps - all the time.

♦ overalls - all the time.

♦ eye protection goggles - when welding, grinding/cutting/

♦ latex gloves - most of the time - especially dealing with