Preventive Maintenance

Service Manual
D Trucks
Group 17
Release 07
Preventive maintenance
Basic service
FM, FH, NH
VERSION2
20154808
Foreword
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The descriptions and service procedures contained in this manual are based on designs
and methods studies carried out up to October 2005.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is judged to have a significant bearing on this manual, supplementary service
bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a

reference to V.S.T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for general
information and no reference is made to V.S.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to have
the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could occur.
Volvo Truck Corporation

Göteborg, Sweden
Order number: 20154808
© 2005 Volvo Truck Corporation, Göteborg, Sweden
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 Truck Corporation.
ENG30497.ihval
Contents
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Basic service ........................................................................................ 2
General, preventive maintenance .......................................................... 2
Driver’s service, optional ........................................................................ 3
Driver’s service, optional ...................................................................... 3
Basic service .......................................................................................... 4
Basic service ....................................................................................... 7
Feedback
1
Group 17 Basic service General, preventive maintenance
Basic service
General, preventive maintenance

Driver service
Basic service
Annual service
Option
Volvo’s preventive maintenance consists of:
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Is carried out by the driver every day and when refuelling, see service booklet in the vehicle
binder.
To be carried out at every engine oil and filter change or every 6 months, whichever occurs first.
To be carried out at least once per year.
Stand-alone section of the basic and annual service that consists of simple checks that the
owner can carry out by, but that can be ordered in conjunction with the basic and annual service.
Additional Are best carried out in conjunction with the basic and annual service. The procedures are
procedures contained in the Service Manual “Additional measures” Group 17.
Lubrication service Lubrication service as per the lubrication diagram for each vehicle, group 175, is carried out in
conjunction with basic and annual service, and also when intermediate lubrication is necessary.
There are record sheets for the basic and annual services as well as the option.
Note: For the lubrication intervals for chassis and cab, and change intervals for oil, filters
and fluids, refer to Service Information Group 175 “Lubrication service and oil changes”.
Because operational conditions can vary depending on how the vehicle is used, it is
important that the service workshop, together with the customer, adapt the service
requirements to suit the vehicle.
Superstructure and trailer maintenance should be adapted to other servicing to ensure

that the services are kept to a minimum.
Vehicles that are driven on wet road surfaces with road salt and sand, and vehicles that
are washed using a high-pressure washer, require more lubrication service.
The illustrations in this service information illustrate components on one variant of the
vehicle. Unfortunately not all components can be shown.
WARNING
Chock a wheel so that the vehicle cannot roll
during the servicing.
2
Group 17 Basic service Driver’s service, optional
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Driver’s service, optional
17725-3
Driver’s service, optional
Record sheet for option – FM, FH, NH VERSION2
Date Name Reg. no.
Mileage Address Telephone no.
WO no. Postal address Delivery date
Carried out by (signature) Chassis type/no. Engine type/no.
Gearbox Customer no.
Final drive
X Rectified without comment 1 Action recommended 2 To be rectified immediately - The point is not
applicable
Check all control lamps in the switches

Check the function and attachment of the starter switch
Check the function of the starter motor. Evaluate engine speed and noise
Check the function of all instruments
Check the function of all controls and switches
Check the control and settings of the seats
Check seat belt condition and function
Check the condition of seats and bunks
Check the condition of the fire extinguisher and its attachment
Check the condition of the windows
Check the function of the window lift mechanisms
Check the condition of the floor, mats and foot steps
Check the function of the roof hatch and engine casing and check for leaks
Check the function of storage compartment locks and closing devices
Check the sun shade and interior sun visors
Test and check all internal lighting and the horn
Check the condition and attachment of the registration plates
Check condition and attachment of wings and mudflaps
Check the tread depth of the tyres
Check the tyre pressure and the valve caps
Check paintwork and panels for damage
Check the rear view mirrors
Check the function of the windscreen wipers and washers
T1007905
3
Group 17 Basic service Basic service
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Basic service
T1008834
Basic service including lubrication and oil change

– FM, FH, NH VERSION2
17744-2 Record sheet for basic service

- FM, FH, NH VERSION2
Date Name Reg. no.
Mileage Address Telephone no.
WO no. Postal address Delivery date
Carried out by (signature) Chassis type/no. Engine type/no.
Gearbox Customer no.
Final drive
X Rectified without comment 1 Action recommended 2 To be rectified immediately - The point is not
applicable
Lubrication, oil and fluid level check [ ] “20 Checking the fuel tank, hoses, pipes and
suspension straps” page 22
[ ] “1 Chassis lubrication” page 7 [ ] “21 Checking the fuel tank ventilation filter” page 22
[ ] “2 Cab lubrication” page 8 [ ] “22 Checking tyre wear” page 23
[ ] “3 Changing engine oil and filters” page 8
[ ] “4 Checking the oil level in the driving front axle” Engine compartment
page 9
[ ] “5 Checking the oil level in the hydraulic bogie lift” [ ] “23 Checking the alternator attachment, electrical
page 10 connections and cab grounding” page 24
[ ] “6 Checking the oil level in the power steering” page [ ] “24 Checking the drive belts and belt tensioners”
10 page 24
[ ] “7 Checking the fluid level in the clutch fluid [ ] “25 Checking for leaks in the engine, engine-driven
reservoir” page 11 power take-off and compressor” page 25
[ ] “8 Checking the coolant level” page 12 [ ] “26 Checking the fuel pipes and lines” page 25
[ ] “9 Checking the fluid level in the windscreen/head- [ ] “27 Checking for exhaust leaks” page 26
lamp washer reservoir” page 12 [ ] “28 Checking the charge air cooler hoses and pipes”
[ ] “10 Checking the air drier” page 13 page 26
Checks in the cab Front suspension, steering gear

[ ] “11 Checking the warning and control lamps” page [ ] “29 Checking the steering shaft universal joint,
15 power steering hoses and pipes” page 27
[ ] “12 Checking fault codes in the vehicle control units” [ ] “30 Checking gaiters and ball joint play” page 29
page 16
[ ] “13 Function check of the parking heater” page 16 Checks under the vehicle
[ ] “14 Checking the service brake for leaks” page 17
[ ] “31 Checking the seal and bearing play on the
driving front axle” page 30
External checks
[ ] “32 Checking the play in the mechanical function of
[ ] “15 Checking the lighting and reflectors” page 18 the clutch” page 30
[ ] “16 Function check of the wipers and washers” page [ ] “33 Checking the seal of the gearbox, transfer
19 gearbox and power take-off” page 30
[ ] “17 Checking the air intake and air deflector” page 19 [ ] “34 Check the automatic gearbox oil cooler for
[ ] “18 Checking the roof-mounted air conditioning” leakage” page 31
page 20 [ ] “35 Checking the seal on the retarder” page 31
[ ] “19 Checking battery attachment, connections and [ ] “36 Checking propeller shafts – universal joints, slide
fluid level” page 20 joints and support bearings” page 31
4
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[ ] “37 Checking the seal on the rear axle and hub [ ] “44 Checking brake callipers and brake discs” page
reduction” page 32 37
[ ] “38 Checking the exhaust pipe and silencer or [ ] “45 Checking the slack adjuster travel” page 38
particle filter” page 32
[ ] “39 Checking the springs and U-bolts” page 33 Test driving
[ ] “40 Checking the lubrication system (central
[ ] “46 Checks after start” page 39
lubrication)” page 33
[ ] “47 Checks during test driving” page 40
[ ] “41 Checking the air suspension bellows” page 33
[ ] “48 Checks after test driving” page 41
[ ] “42 Checking the brake linings” page 34
[ ] “49 Finish” page 41
[ ] “43 Checking brake cylinders, slack adjusters and
forks” page 36
Battery status Test code

Front/internal battery
Rear/external battery
←Note the values seen from the cab and backwards in the boxes below←
Brake lining - measured Right
thickness in mm
Left
Brake levers - Right
measured travel in
Left
mm
Remarks on the tyre Right
wear patterns
Left
T1006800
Additional procedures [ ] 23414-3 Filter for fuel tank ventilation, replace

[ ] 25426-2 Particulate filter insert, cleaning
[ ] 17504-2 Lubrication of lubrication points [ ] 25453-2 EGR pipe, cleaning
[ ] 17523-3 Gearbox, oil and filter, change [ ] 25627-3 Filter insert in air cleaner, replace
[ ] 17527-3 Rear axle, oil change [ ] 26010-2 Coolant, change
[ ] 17528-3 Retarder, oil change [ ] 26123-3 Coolant filter, replace
[ ] 17530-3 Transfer gearbox, oil change [ ] 26307-3 Fan belt, replace
[ ] 17561-3 Rear axle with hub reduction, oil change [ ] 32204-3 Charging regulator, replace
[ ] 17577-3 Power take-off, oil and filter, change [ ] 32123-3 Alternator belt, replace
[ ] 17582-3 Driven front axle, oil change [ ] 43705-3 Ventilation filter, replace
[ ] 17706-2 Cab heater, maintenance in accordance [ ] 56166-3 Air drier kit, replace
with Service Manual [ ] 77145-3 Wheel nuts, retightening, all
[ ] 21413-2 Valves and unit injectors, adjustment [ ] 87425-2 Radiator, roof mounted A/C, replace
[ ] 23306-3 Fuel filter, replace (1 off)
[ ] 23311-3 Water separator, filter replace
5
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Adjustment and repair may be carried out immediately to a maximum sum of ______ If this is exceeded the customer
must be contacted.
The following comments have been made by the customer. The driver’s report must be attached.
No. Action - description
6
D
17744-2
Basic service
Regarding chassis lubrication and oil changes see service protocol
Basic service including lubrication, oil and filter change in engine, oil
and fluid level checks
When changing oil it is essential that as much oil as
possible is drained off and changed in the component.
For this reason, remember that oil changes are best done
after driving, i.e. when the oil is warm and fluid.
In conjunction with oil changes, the oil filters must also be

changed. The old oil filters must always be scrapped.
Always check the oil level after filling.
WARNING
Hot oil can cause burns. Use protective gloves.
For information about oil change volumes, oil and

grease grades, viscosity and oil change intervals, see
service information “Lubrication service and oil change”
group 175.
For the report sheet, refer to “Basic service” page 4
1 Chassis lubrication
1
• Lubricate in accordance with each vehicle’s
lubrication schedule. See Service Information,
Group 175.
1 Grease nipple positions are shown on the
lubrication chart. Make sure that each lubrication
point is properly lubricated. Lubricate until new
grease forces its way out and is visible. If no
grease forces its way out there is something
wrong and action must be taken immediately.
2 The parking brake on vehicles with drum brakes

must be released when lubricating so that grease
can enter freely to the brake cams.
• Vehicles with central lubrication:

Check whether the lubrication reservoir needs filling
and top up if necessary.
To top up the lubricant, remove the cap on the pump.
Then remove the protective cap from the filling valve and
T8008270
pump in lubricant, using female union 9808639, until
the level reaches the max. marking.
Note: It is of extreme importance that the correct

equipment and the correct quality of grease are used
when filling so that dirt does not contaminate the grease
For information concerning lubrication grades, refer
to the service information “Lubrication service and
oil change” Group 175.
7
2 Cab lubrication
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1
Lubricate in accordance with each vehicle’s lubrication
schedule. See Service Information, Group 175.
3 Changing engine oil and filters

1
Drain plug (A) is located in the bottom of the oil sump.
Drain the oil after driving the vehicle so that it is still flows
easily. Replace the full-flow filter (B) and the bypass filter
(C) at the same time as the oil is changed.
CAUTION
Hot oil can cause burns. Take care to avoid spilling oil
when topping up. Oil spilt on the engine can affect
cooling performance.
• Remove any sound baffles under the engine.
• Clean around the drain plug.
• Remove the drain plug. Tighten the drain plug using

a torque wrench, see service information group 21
for further information.
T1007362 • Drain the oil.
• Clean the filters and filter brackets externally to prevent

dirt from getting in when the new filters are fitted.
• Remove the existing oil filters with oil filter tool

9998487 and discard them. The oil filters are
disposable and must always be scrapped after use.
Note: The filters must not be cleaned. They can only be
replaced. Always replace the filter when changing the oil.
• Clean the sealing surface (2) for the oil filter seal
and the surrounding surfaces on the filter bracket
thoroughly.
• If the oil filter bracket has a protective lip (1) for the oil
filters, clean the inside of this lip carefully.
• Apply a thin film of oil to the rubber seals on the

new oil filters.
• Hand tighten the oil filter until the rubber seal makes
contact with the mating surfaces.
• Then turn an additional 3/4 to one complete turn (or as

specified by the marking on the filter).
• Check the oil filler system and dipstick.
• Fit the drain plugs with new gaskets and fill with
fresh oil Use the side filler pipe on the engine when
T1007781 filling with oil.
• Refit any sound baffles under the engine.
For information concerning oil grades, oil change volumes

and oil change intervals, refer to the service information
“Lubrication service and oil change” Group 175.
8
Checking the oil level
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1
Note: Under no circumstances must the level go
below the lower marking. Neither should the level be
above the upper marking on the dipstick.
• Check that the oil level lies within the top half of the
section of the dipstick between max. and min.
• Start the engine and check for oil leaks.
• Switch off the engine and check the oil level after a few
minutes. Top up as necessary.
4 Checking the oil level in the

driving front axle
1
Note: If, depending on the service interval of the driving
front axle, an oil change must be carried out, see Future
action, op no. 17582-3.
Front axle wheel gears
The front axle must be raised.
• Clean around the level/filler plugs (A) for the wheel

gears.
• Turn the wheel so that the level mark by the level/filler

hole is horizontal.
• Remove the level/filler plug and check that the oil level
reaches up to the edge of the filler hole.
T1007657 • Top up with oil if necessary.
• Refit the level/filler plugs for the wheel gears. If the

plug seal rings are damaged, replace the seal rings.
Front axle differential carrier
• Clean around the level/filler plug (A).

• Remove the level/filler plug (A) and check that the oil
level reaches up to the edge of the filler hole.
• Top up with oil if necessary.
For information about restoring the oil level in the driving

front axle, see service information“Lubrication service
and oil changes” group 175.
• Refit the level/filler plug (A).
If the filler plug has a sealing washer, the sealing washer

must be replaced.
For information about oil grade, see service information

T1007658 “Lubrication service and oil changes” group 175.
9
5 Checking the oil level in the
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hydraulic bogie lift
1
The bogie must be lowered and the bogie lift moved to
its end position.
• Check that the oil level is between the markings on

the oil reservoir.

“Lubrication service and oil changes” group 175.
T1006377
6 Checking the oil level in the power

steering
1
• Clean around the cap and the dipstick.
• Check the oil level. When the engine is not running,

the level should reach the MAX mark on the dipstick.
Dipstick in the oil reservoir on vehicles with hydraulically

steered pusher axle and hydraulically steered trailing
wheel axle:
Disconnect the connector to the electrical cable on

the dipstick. Check the oil level. When the engine is
not running, the level should reach the MAX mark
on the dipstick.
T1006378
Certain vehicles with 2-circuit steering systems have twin

oil reservoirs for the power steering.

T6007837
10
7 Checking the fluid level in the
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clutch fluid reservoir
1
• Check that the level in the clutch fluid reservoir is in
the middle of the reservoir or between the MIN and
MAX markings, if there are any.
• Top up the reservoir with brake fluid if necessary.
To avoid fluid running out and damaging the paintwork,

take care when topping up with fluid and check that the
reservoir cap is securely tightened.
Note: In the South American market the reservoir

must be sealed.
T1007731
C0002139
FM, FH, South American market

Note: It is important that the fluid has the correct grade,
refer to the service information “Lubrication service and
oil change” group 175.
Cleanliness is important when topping up clutch fluid.
The pourer being used must be absolutely clean
and must not contain any traces of dirt or any type of
mineral based grease or oil.
C0002140
NH, South American market
11
8 Checking the coolant level
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1
Note: If, depending on the coolant change interval,
the coolant is to be changed, see Future action, op.
no. 26010-2.
• Top up with water and 50% concentrated coolant as

necessary, mix before topping up. The fluid level must
be between the MIN and MAX markings on the
expansion tank when the engine is cold.
For information about water quality, see service

information group 26.
T1007365
Note: If the quality of the water does not fulfil the
specifications, the ready-mixed coolant from Volvo
should be used.
Only use concentrated coolant approved by Volvo,

which contains special anti-corrosion additives and is
suitable for Volvo engines. Mixing this with concentrated
coolant of a different type can result in inferior corrosion
protection and subsequent damage to the engine.
• Check that the filling and pressure caps are securely

tightened by hand.
T1007465 For information about coolant, see service information
9 Checking the fluid level in the

windscreen/headlamp washer
reservoir
1
T1007366 Top up washer fluid if necessary.
C1000029
12
10 Checking the air drier
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1
Note: If, depending on the service interval of the air drier,
the desiccant must be changed, see Future action.
For information on air drier service intervals, see service

information “Lubrication service and oil changes”
group 175.
CAUTION
Follow the instructions carefully to avoid injury or
damage to products or equipment.
Note: Check that the parking brake is applied.

T1007367 • Drain off any condensation from the compressed
air tanks.
• On vehicles with air driers there should be no water in

the compressed air tanks.
If there is no water in the compressed air tanks this

means that the air drier is functioning correctly.
• Drain the compressed air tanks to make sure the

pressure regulator cuts in. Start the engine and check
that no leakage occurs from the air drier silencer while
the compressor is charging.
If there is an air leak from the silencer on the air

drier, use Service Information group 56 as a guide for
rectifying the air drier.
• Run the engine until the pressure regulator cuts out the
compressor. Switch off the engine. Check for about 30
seconds after the regeneration tanks has emptied, that
no air is leaking from the air drier silencer.
If there is an air leak from the silencer on the air

drier, use Service Information group 56 as a guide for
rectifying the air drier.
• Clean around the desiccant reservoir.
• Evacuate the compressed air system, use nipple

9992976.
• AIRDRY (HALDEX)
1 Remove the four screws that hold the reservoir
together with the drier insert.
2 Lift off the reservoir together with the drier insert.
T5008850
13
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AIRDRY1, AIRDRY-E (WABCO)
1 Unscrew the desiccant reservoir using filter key
9998313 or 9999179.
• Check the air drier housing for carbon deposits.
Note: Note on the record sheet if there are carbon

deposits in the air drier housing.
If it is deemed that the carbon deposits will cause
a problem before the next service, see service
information group 56 for checks and procedures.
In conjunction with these checks and procedures, the

compressed air pressure drop should also be checked,
see point 26 in Annual Service, service information
group 17.
• AIRDRY (HALDEX)
T5012025 1 Replace the O ring. Apply a thin layer of grease to
the new O ring. Fit it into the housing.
2 Refit the reservoir with desiccant for the cartridge.

Fit the four mounting screws and tighten
alternately. Tightening torque 45±2 Nm.
• AIRDRY1 (WABCO)
1 Apply a thin layer of grease to the desiccant
T5012024
reservoir sealing ring and to the threaded dowel.
2 Screw on the cartridge by hand until the seal is in
contact with the air drier housing. Then turn it
one more turn (approx.15 Nm) by hand or as
marked on the desiccant reservoir.
• Start the engine, charge the compressed air system.

Check that there are no leaks from the air drier.
For information about the air drier service intervals, refer

to the service information “Lubrication service and oil
T5012026
changes” Group 175.
14
Checks in the cab
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11 Checking the warning and
control lamps
Use the Vehicle Binder as an aid.
Instrument with large display.

1
The engine must be switched off and the starter key must
be in the drive position.
The warning and control lamps are tested using the

control lever on the right-hand side of the steering wheel
and the instrument display.
•
T1007735 CONTROL LAMP TEST
GAUGE TEST
DISPLAY TEST
BUZZER TEST
Bring up the MENU: FAULT DIAGNOSIS/INSTRUMENT

TEST/CONTROL LAMP TEST on the display.
• Press “SELECT” (2) when the cursor on the display

shows “CONTROL LAMP TEST”.
The warning and control lamps on the instrument display
are turned on and off at 5 second intervals.
Stop the test by pressing “Esc”
T3008810
Instrument with small display.

2
To test the warning and control lamps on this type of
instrument, the engine must be switched off and the
starter key must be in the drive position. All warning
and control lamps should then light.
T1007698
15
12 Checking fault codes in the
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vehicle control units
1
When testing, the engine must be switched off and the
starter key must be in the driving position.
To communicate and check fault codes on the instrument

driver information display use the control lever on the
right-hand side of the steering wheel.
• Check using the control lever and display whether

there are fault codes stored in any of the vehicle
control units.
• Note down and then rectify any possible fault codes.
• Reset the fault codes after rectification.
Fault codes can also checked using a PC, through the

T1006725 data link connector located under the instrument panel
on the driver’s side of the vehicle.
Use service information group 03 and fault code

information for each respective system as an aid.
13 Function check of the parking

heater
1
Use the parking heater operator’s manual as an aid.
• Start and run the parking heater for 15 minutes

to check its function.
WARNING
Check the heater for clogging or leaking exhaust pipes.
Note: Do not stop the parking heater until it has been

running for at least 15 minutes.
• If the heater malfunctions check it and rectify the fault.
Note: Annual maintenance must be carried out in

good time before winter.
T1007410
Use the service literature, group 87, as an aid.
Quick start/manual stop of parking heater
Quick start Press the switch once to start the

parking heater
Manual stop Press the switch once to switch off the
parking heater.
T8008457
16
14 Checking the service brake for
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leaks
1
• Charge the compressed air system.
• Depress the brake pedal and check the compressed

air gauges and listening to the service brake to check
that it is not leaking air.
An alternative to starting the engine to fill the compressed

air system is to use the pressure booster 9810621.
T3014323 If the compressed air system is filled from an external

compressed air supply, filling must always take place
through the air drier filler nipple to avoid moisture in the
compressed air system.
T7006749
T1007733
17
External checks
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15 Checking the lighting and
reflectors
1
•
•
•
Check all external lighting.
Check that all lamp glass is intact.
Check that the reflectors are intact and that none

are missing.
T3014325
a 0– position
b Parking lights
c Driving running lights (high

beam and low beam)
d High beam and campaign

lights (spot lamps)
1 Light switch
Front fog lamps: Press

the light switch
Rear fog lamps: Pull the
light switch out
2 Front fog lamps indicator

lamp
3 Rear fog lamps indicator

lamp
4 Instrumentation lighting
5 Headlamp adjustment
(extra equipment)
6 Hazard warning lights
18
16 Function check of the wipers
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and washers
1
• Check the condition of all wiper arms, wiper blades,
washer tubes and washer nozzles.
T3014359
17 Checking the air intake and air

deflector
1
• Check that the intake pipe is intact and that the rubber
bellows seals the pipe to the air cleaner housing.
• Check the attachment of brackets, rubber cushions

and bolted joints for the air intake and spoiler.
• Check that there are no cracks on the spoiler or

its mountings.
T1006759
19
18 Checking the roof-mounted air
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conditioning
1
• The air intake with filter is located on the roof of the cab.
• Remove the cover (1), radiator (2) and strainer (3).

Note: If, depending on the replacement interval of the
radiator, the radiator is to be replaced, see Future
action, op. no. 87425-2.
• Wash the radiator.
CAUTION
Do not use a high-pressure washer.
C0002020 • Wash the strainer until all residue is gone.
• Fit the strainer (3), radiator (2) and cover (1).

• Remove the filter (A).
• Pour water onto the back of the filter until all residue is
gone.
• Install the filter.
• Fill the container with distilled water.
C0002001
19 Checking battery attachment,

connections and fluid level
1
WARNING
Batteries contain corrosive sulphuric acid.
Wear safety goggles when working on batteries.
• Check that the batteries are not dirty.
• Check that the batteries do not leak.
• Check that the batteries are attached securely.

Note: Securing the batteries too hard can damage them.
20 T1007896
D
Check the batteries using battery analyser 9812515 or
9812518.
• Check that the fluid level in the battery

cells is approximately 18–28 mm above
the cell plates (South America), and 5–10
mm above the cell plates (Europe).
• Top up with distilled water if necessary, to max. 28 mm

T0011087 above the cell plates (South America), and 10 mm
above the cell plates (Europe).
• Check that the terminals are not corroded or damaged.
• If necessary, clean the battery cable terminals and

lubricate them.
T3008164
• Check that the cable insulation is undamaged and that
the cables are correctly located.
• Check the attachment of all ground cables.
• Check the ground cables from the battery negative

terminal to the engine mounting. Ensure that it is
intact and undamaged.
Safety precautions when charging
• Always use safety goggles.
• Unscrew all the filler caps but leave them in their holes.
T1008197 • Turn off the main switch if there is one.
• Disconnect at least one pole shoe from the battery.

(Certain control units are supplied with power directly
from the battery.) Boost chargers can generate a very
high voltage which can damage electronic equipment.
• Charging must take place in a well-ventilated area.
• Smoking is not permitted. Avoid naked flames and

sparks as explosive oxyhydrogen gas is produced
during charging.
• Switch off the charger before the charging clamps are

fitted/removed.
CAUTION
Follow the instructions carefully to avoid injury or
damage to products or equipment.
For more information about batteries and battery

charging, see service information group 31, “Batteries”.
21
20 Checking the fuel tank, hoses,
D
pipes and suspension straps
1
• Check that there are no cracks or leaks on the tank.
• Check that the tank suspension straps are not loose

or cracked.
• Check that pipes, hoses and electrical cables from the

combined tank unit are clamped and are not chafing.
Check that are there are no leaks.
T2017419
21 Checking the fuel tank ventilation

filter
1
This filter is used in certain markets.
Note: If, depending on its service interval, a fuel tank

ventilation filter must be replaced, see Future action,
op. no. 23414-3.
• Check that the air intake for the filter is free of dust
and dirt.
• Check that the filter and ventilation pipe are

undamaged and secure.
For information about the filter service interval, see
service information “Lubrication service and oil changes”
group 175.
T1006941
22
22 Checking tyre wear
D
1
Check that the tyres have a normal wear pattern.
Note: Make a note of any remarks in the record sheet!
Front tyres
• Check the front tyres for pitting, which would indicate

a balance problem, extreme wheel bearing play,
spindle bearings or no inertia point in the centre
of the steering gear.
• Check the front tyres for feather-edging, which would

indicate toe-in problems.
• Check the front tyres for abnormal wear on one half of

the tyre, which would indicate camber problems.
Rear tyres
• Check the rear tyre treads for abnormal heel-and-toe

wear, which could be caused by unfavourable twin
wheel mounting.
T1008206 • Check for a visible tendency for wear marks between

twin wheel mounted tyres. Make a note of any wear
marks.
• Check for a tendency to toe-in-wear, which would

indicate an out-of-line axle.
Spare tyre
• Check the condition of the spare tyre.
23
Engine compartment
D
Remove the sound baffles from the frame members by
the engine. Remove any sound baffles under the engine
to to facilitate work.
23 Checking the alternator

attachment, electrical connections
and cab grounding
1
Note: If, depending on the its replacement interval, the
charge regulator must be replaced, see Future action,
op no 32204-3.
• Check the alternator mounting.
• Check that the electrical connectors on the alternator

are secure.
• Check that the ground cable between the cab and the
cylinder block is intact and undamaged.
For information about the charge regulator service

interval, refer to the service information “Lubrication
service and oil changes” group 175.
T1007555
24 Checking the drive belts and

belt tensioners
1
Note: If, depending on its replacement interval, the
V-ribbed belts must be replaced, see Future action, op.
no. 26307-3 and 32123–3.
• Check that none of the ribs on the drive belts have

fallen off.
• Check that the drive belts have no cracks. Replace

cracked belts.
• There must be no dirt or grease on the drive belts or

belt pulley contact surfaces.
T1007554
24
D
Check the automatic belt tensioner.
1 Check the function of the belt tensioner.

2 Release the tension on the belt tensioner with a
draw handle and check the bearings in the belt
tensioner rollers and in any support rollers.
For information about V-ribbed belt service intervals,

see service information “Lubrication service and oil
changes” group 175.
T1007557
25 Checking for leaks in the engine,

engine-driven power take-off and
compressor
1
• Check that the engine does not leak oil or coolant.
• Check that fittings, flanges and hose connections do

not leak.
• Check that hoses or pipes do not chafe and are

not cracked.
• Check that the engine-driven power take-off or lines

do not leak oil.
• Check that the compressor does not leak oil or coolant.
T1007729
26 Checking the fuel pipes and lines

1
• Check that the hose and pipe fittings for the fuel
lines do not leak.
• Check that the fuel lines do not leak or chafe.
T1007369
25
27 Checking for exhaust leaks
D
1
Exhaust leakage can be seen as soot deposits.
• Check for exhaust leaks around the exhaust ports on

the cylinder heads, by manifold joints and flanges.
• Check for exhaust leaks around the exhaust ports,

the exhaust brake or around the jointing clamp for
the front exhaust pipe.
T1007370
28 Checking the charge air cooler

hoses and pipes
1
• Check that the hoses and pipes between the engine
and the charge air cooler are intact and do not chafe.
• Check clamps and bolted joints for the hoses and

pipes between the engine and the charge air cooler.
T1007371
26
Fore carriage, steering
D 29 Checking the steering shaft

universal joint, power steering
hoses and pipes
1
• Check that the steering shaft

universal joint on the steering gear
is secure and that there is no play.
• Check that the power steering hoses and pipes are

intact and do not chafe.
T1006795
• Check that the hoses and pipes for the control system
for the hydraulically steered pusher axle or trailing
wheel axle are intact and do not chafe.
T1007727
T6007835
27
D
Check that clamps for pipes and hoses are secure.
• Fit the sound baffles to the frame members by the
engine and any sound baffles under the engine.
For work on the control system use service information

group 6.
WARNING
The hydraulic fluid in the trailing wheel or pusher axle
control system is under constant pressure (15 bar),
even when the engine is switched off. So follow
the instructions carefully to avoid injury or damage
to products or equipment. Carelessness can lead
to minor or moderate personal injury or damage
to the product.
T1008201
28
30 Checking gaiters and ball joint
D
play
1
• Check that the rubber gaiters on link rod ball joints;
track rods; steering rods; extra steering hydraulic
cylinders; and the master and centring cylinder for the
hydraulically steered pusher axle or trailing wheel axle;
are intact and sealed.
If any of the rubber gaiters are damaged or cracked, the

ball joint must be replaced.
Note: A damaged or cracked gaiter means that the

ball joint soon wears out.
• Turn the wheels straight ahead. A worn ball joint has

its greatest play in this position.
T1006482 Check the axial play in ball joints with dial gauge 9808092
and magnetic holder 9812528.
• Press the ball joint together as much as possible using

adjustable pliers. Zero the dial indicator.
• Separate the ball joint as far as possible using lever

1158289. The greatest permitted axial play is 2 mm.
If the axial play exceeds 2 mm, the ball joint must be

replaced.
If unsure about axial play in the ball joints, use service

information group 6 to help.
T6009383
T6009384
29
Checks under the vehicle
T4011554
D
31 Checking the seal and bearing
play on the driving front axle
1
•
•
Check that front axle and wheel gears do not leak oil.
Check that there is no play in the pinion bearing by
lifting the front axle gear follower up and down. Any
movement indicates a loose nut or bearing.
32 Checking the play in the

mechanical function of the clutch
1
• Remove any sound baffles under the gearbox.
• Check that there is no play in the release lever.
• Check that the gaiters for the clutch servo and the
release lever ball joint are intact.
T4017821
33 Checking the seal of the gearbox,

transfer gearbox and power take-off
1
• Check that the gearbox, manual or automatic, does
not leak oil or coolant.
• Check that the power take-off or transfer gearbox

do not leak oil.
• Refit any sound baffles.
• In the event of a leak, check the oil level.
T1008199
30
34 Check the automatic gearbox oil
D
cooler for leakage
1
• Check that there are no oil or coolant leaks by the
oil cooler.
• Check that there are no oil or coolant leaks from pipes

or hoses to the oil cooler and gearbox.
T1006782
35 Checking the seal on the retarder

1
• Check that there are no oil or coolant leaks by the
retarder.
• Check that there are no coolant leaks from hoses or

pipes between the engine and retarder.
T0008639
36 Checking propeller shafts –

universal joints, slide joints and
support bearings
1
• With the power transmission in neutral check the
propeller shafts for bias and damage.
• Feel each universal joint and check for wear. There

should be no play in the joints.
• Visually check that screws for bearings and flanges

are tightened, and that any circlips are in position.
• If the propeller shaft is to be lubricated, lubricate the

lubrication points in accordance with the lubrication
chart.
T1006745
31
D
Turn and lift the splined joints and check for wear.
Side and top wear in the booms can cause movement

in the slide joints, which would cause vibration and
imbalance. There is no definite limit for this play, but it
should be taken into consideration and noted, so that it
can be pointed out to the customer.
• Check the attachment of the support bearing

suspension and the condition of the rubber component.
The rubber must have no play in the holder.
37 Checking the seal on the rear

axle and hub reduction
1
• Check that the rear axle does not leak oil.
The outlet to the rear axle venting hose may emit a

certain amount of oil mist, which is normal.
• Check that the hub reduction hub does not leak oil.
T4012341
• Check that the air vent hose is not clogged.
T4011521
38 Checking the exhaust pipe and

silencer or particle filter
1
Note: Vehicle equipped with a particle filter: If, depending
on the its replacement interval, the particulate filter be
cleaned, see Future action, op no 25426-2.
• Check the condition of the metal on the exhaust pipe

and silencer or particle filter, if the vehicle is equipped
with one.
• Check the flexible hose and clamps.
• Check the suspension of the exhaust pipe and silencer

or particle filter for cracks, loose screws, clamps,
brackets and protective plates.
For information about the particulate filter service interval,

T1008198
see service information “Lubrication service and oil
changes” group 175.
32
39 Checking the springs and U-bolts
D
1
• Check the springs for cracked or loose leaves which
could mean that the centre screw is broken.
• Check the U-bolts. Loose U-bolts are indicated

when the spring assembly is not completely pressed
together and/or the spring assembly has moved on the
axle by the anchorage.
T1006450
40 Checking the lubrication system

(central lubrication)
1
• Check that the pump unit, hoses, nipples and
distributor valves for the central lubrication system do
not leak, are undamaged and are securely attached.
Also check that none of the clamps are loose.
• Check that no nipples or hoses have come loose or

been damaged at any lubrication point.
• Check that no hoses chafe or have come loose by the

front axle (as a result of steering movements).
• Check that no lubrication point connected to the

central lubrication system is not lubricated (dry). If
any lubrication point is not lubricated take action
immediately.
T9007322
41 Checking the air suspension

bellows
1
• Check that the air bellows do not leak.
• Check that the air bellows are undamaged.
T1007419
33
42 Checking the brake linings
D
Drum brake
1
• Check the thickness of the brake lining through the
inspection hole in the brake shield. The minimum
permitted thickness of the brake lining is 5 mm.
• Check that there is no grease leaking from the hubs

onto the brake linings.
Note: Make a note of the brake lining thickness in

the record sheet!
Use service information group 5 as a guide for working on

the brake system.
Disc brakes
T1006743
The brake callipers for disc brakes are fitted with two
wear sensors, one mechanical and one electrical.
The electrical wear sensor shows the average value of

the brake lining wear on both brake pads.
Use the PC tool to read off the stored value of remaining

brake lining as a percentage for each wheel.
The mechanical wear sensor shows lining wear on the

outer brake pad.
Checking the brake lining wear, mechanical wear sensor.
A. New brake pads, brake lining thickness
20 mm.
B. Replacement limit, brake lining thickness
4 mm.
• Check the brake lining thickness on the brake pad

using the mechanical wear sensor located on the
brake callipers.
T5011027
The mechanical wear sensor gives a rough indication of
the lining thickness. Its function assumes that the inner
and outer brake linings are equally worn.
The figure shows the wear sensor position with new brake
pads, brake lining thickness 20 mm.
• Check that the wear sensor is not stuck and can
move freely.
T1007722
34
D
Measure the protruding part of the wear sensor to
estimate the lining thickness of the brake pads.
The minimum permitted thickness of the brake lining
is 4 mm.
the record sheet!
The figure shows the position of the wear sensor for worn
brake linings, approx. 4 mm left.
Use service information group 5 as a guide for working
on disc brakes.
Checking the brake lining wear with the PC-tool
T1007723 Use the PC tool possible to read off the stored average
value of the lining wear on both brake pads as a
percentage for each wheel.
• Connect the PC tool to the vehicle data link connector,

located on the driver’s side on the lower edge of
the instrument panel.
T0009521
• Use the PC tool to read off the stored average value
for the remaining brake lining on each wheel. At a
value of 20% the brake lining is approx. 4 mm, which
is the minimum permitted brake lining thickness.

the record sheet!
If the brake lining thickness on any wheel deviates from
the average, investigate the cause of this.
Use service information group 03 and group 5 as guides

when checking brake lining wear and for procedures
on disc brakes.
T3008754
35
43 Checking brake cylinders, slack
D
adjusters and forks
1
• The compressed air system must be charged. An
alternative to filling the system by starting the engine is
to use pressure booster 9810621.
To fill the compressed air system from an external

compressed air supply, use the air drier filler nipple to
avoid moisture getting into in the compressed air system.
Chock the wheels so that the vehicle cannot begin to roll.
T7006749
• Release the handbrake and apply the footbrake using
a pedal jack or assistant.
• Check that the brake cylinders do not leak.
• Check that the brake cylinders and brake brackets are

secure, and not cracked.
T1007733
T0008508
• Check that slack adjusters and brake forks are
fault-free.
T1008202
36
44 Checking brake callipers and
D
brake discs
1
• Check the brake callipers for
cracks, corrosion and attachment.
• Check the brake discs for wear, cracks and grooves.
T5011015 On axles where protective plates cover the brake

discs:
1 Check the edges of the brake discs for cracks.
2 Also check the condition of the brake discs

through the ventilation slots in the protective
plates.
3 On axles with single wheels, check the condition

of the brake discs through the holes in the
wheel rims.
T5011102
• Check that the sensor wiring in brake callipers and

brake anchorages is clamped undamaged.
• Check that the protective caps for brake adjustments

are intact and in place.
• Check that there is no grease leaking from the hub.
This can affect the brake discs and brake pads.
If in doubt about the condition or serviceability of brake

components and wear, cracks and minimum dimensions
on brake discs, see service information group 5.
T1007724
37
45 Checking the slack adjuster
D
travel
1
Check the function of the automatic adjustment
mechanism by measuring slack adjuster travel C.
Carry out the check at a brake pressure of 6 bar.
Chock the wheels so that the vehicle cannot begin to roll.
• Release the handbrake and apply the footbrake using

a pedal jack or assistant.
• Measure distance b.
T1006451
• Release the foot brake and measure distance a.
• Calculate the stroke C (C= b-a).
Note: Make a note of the values in the record sheet!
Slack adjuster travel C must never exceed 51 mm at

6 bar and automatic adjustment. Minimum permitted
travel at 6 bar is 17 mm. The difference in travel on the
same axle must not exceed 5 mm.
Guide values for travel during automatic

adjustment
A B C
16 125 30
20 125 30
24 155 40
24 170 45
27 170 45
30 155 45
A = size of brake cylinder in square inches.
B = length of slack adjuster in mm.

C = guide value for slack adjuster travel in mm (for
cold brakes).
Note: Somewhat longer travel lengths are possible

without there being a fault in the automatic slack adjuster.
The correct travel shows that automatic slack adjustment

is operating correctly.
Checking slack adjuster travel without

automatic adjustment
For vehicles without automatic adjustment, the following
travel lengths apply when adjusting at 6 bar:
Slack adjuster length (B) Travel (C)
125/155 mm 25-30 mm
170 mm 35-40 mm
38
Test drive
D
A short distance, only to verify certain noted estimates.
Note: Use the operator manual of each vehicle as a

guide.
46 Checks after start

1
• Check that the height and length adjustment of the

steering wheel can be carried out. Check that the
steering wheel is locked in the set position.
• Check that warning lamps, control lamps and

instruments are working.
• The oil pressure and charge warning lamps must

go out immediately the engine has been started.
Check that the engine oil pressure gauge does not
indicate a pressure.
• The low coolant level symbol or warning lamp must

be out.
• The cab locked symbol or warning lamp must be out.

This indicates that the cab is properly locked.
• The pusher axle and trailing wheel axle steering

system warning lamp must be out.
• The service brake warning lamps must be out when

the compressed air system is charged.
• The parking brake warning lamp must light when the

parking brake is activated.
• The anti-lock brakes control lamp must be lit.
• Check the centring function of the hydraulically steered

pusher axle or trailing wheel axle:
1 Turn the wheels (front axle, pusher axle or trailing
wheel axle wheels).
2 Switch off the engine.

3 Turn the ignition key to the drive position. At the
same time check that the pusher axle or trailing
wheel axle wheels carry out a centring movement.
When the front axle wheels are turned to the straight

ahead position, the pusher axle or trailing wheel axle
wheels start turning in the opposite direction. When the
front axle wheels are almost at the straight ahead
position, the pusher axle or trailing wheel axle wheels
centre themselves. After this, the steering movements of
both axles track each other.
Note: The centring function is a safety function, and
should always be checked. If in doubt about the centring
function for the pusher axle or the trailing wheel axle, see
service information group 6.
Note: The information lamp and the warning symbol
for low air pressure in the air suspension system must
T3014466 be out before the vehicle is driven.
Note: Never start driving if the brake system or parking
brake warning lamps are lit.
T3014402
39
D
47 Checks during test driving
1
•
Check that speedometer/tachograph, odometer and
other instruments function.
The pressure gauges for the brake system must be
within their normal values.
Check that the vehicle steers satisfactorily without

any imbalance.
• Check that the brakes are working properly and do not

pull to one side or bind.
• Check that the exhaust brake is working properly.
Note: The D12 engine must be warmed up before the

VEB (Volvo Engine Brake) works.
• Check that the retarder is working properly. Apply

the retarder carefully.
If the compact retarder oil has been changed drive at
an approximate speed of 50 km/h. Apply the retarder 5
times in position 2 for about 5 seconds each time.
• Listen and try to determine if there is any exhaust gas

leakage under load.
• Check that the anti-lock brakes control lamp goes out.

If the lamp does not go out, or if it goes out and then
lights again, there is a fault in the system.
• Check that the clogged air cleaner symbol or warning

light does not light when driving.
• Check that clutch and gearbox, manual or automatic,

operate properly.
• Check that the differential lock, engagement of front

wheel drive, and corresponding control lamps are
working properly.
• Check that there are no fault codes displayed in

the instrument panel Powertronic/Geartronic/I-shift
gearbox display. Make a note of any fault codes!
• Check that the engine has the correct operating

temperature (at least 75 C).
• Check that the heating system and climate control

system are working.
• While driving, check that the windscreen wipers work

and that their sweep is correct.
• While driving, check that the windscreen washer works

and that the jets are aimed correctly.
40
48 Checks after test driving
D
1
• Check the application of the parking brake by carefully

allowing the vehicle to pull with the parking brake
is applied.
• Check that the power take-off re-engagement interlock

is working. If the engine is switched off with the power
take-off engaged, the power take-off is disengaged.
When the engine is restarted the power take-off is
disengaged despite the switch being in the on position.
• Listen for abnormal noise from the engine

compartment.
• Check that the joints of the exhaust pipe and silencer

are not leaking.
• If the vehicle has an automatic gearbox, carry out a

final check of the oil level when the gearbox is still at
operating temperature after the test drive.
• Apply the parking brake.
• Put the gear selector into neutral with the engine

running at approximately 1000 rpm.
• Wipe the dipstick with clean, lint-free paper.
• Check the oil level on the dipstick.
• Top up or drain oil if necessary. Make sure the oil

is clean. Dirt in the oil can damage the gearbox.
• Check the display to ensure that there are no fault

codes stored in the vehicle control units. Rectify any
fault codes using the relevant service information.
• Check that there are no oil or fluid leaks.
49 Finish
1
• Wipe off door handles, the steering wheel and controls.
• Wipe off the floor mat.
41
D
Feedback
One of our objectives is that workshop personnel should have access to correct and
appropriate service manuals where it concerns fault tracing, repairs and maintenance.
In order to maintain the high standards of our literature, your opinions and experience
when using this manual would be greatly appreciated.
If you have any comments or suggestions, make a copy of this page, write down your
comments and send them to us, either via telefax or mailing directly to the address
listed below.
To From
To .......................................................................
Volvo Parts Corporation .......................................................................
Dept. Operational Development 31001 .......................................................................
S-405 08 GÖTEBORG .......................................................................
.......................................................................
Fax +46 31 665858 .......................................................................
.......................................................................
Comments/proposals
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Concerns Service Manual: ...........................................................................................................................

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Volvo Truck Corporation

Göteborg, Sweden
20154808 English 0000.2008.05

Preventive Maintenance

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Service Manual

The new edition of this manual will update the changes.

In service procedures where the title incorporates an operation number, this is a

Volvo Truck Corporation

Order number: 20154808

© 2005 Volvo Truck Corporation, Göteborg, Sweden

All rights reserved. No part of this publication may be reproduced, stored in

General, preventive maintenance

Superstructure and trailer maintenance should be adapted to other servicing to ensure

Date Name Reg. no.

Mileage Address Telephone no.

WO no. Postal address Delivery date

Carried out by (signature) Chassis type/no. Engine type/no.

Gearbox Customer no.

Check all control lamps in the switches

Basic service including lubrication and oil change

17744-2 Record sheet for basic service

Date Name Reg. no.

Mileage Address Telephone no.

WO no. Postal address Delivery date

Carried out by (signature) Chassis type/no. Engine type/no.

Gearbox Customer no.

Checks in the cab Front suspension, steering gear

Battery status Test code

Additional procedures [ ] 23414-3 Filter for fuel tank ventilation, replace

No. Action - description

In conjunction with oil changes, the oil filters must also be

For information about oil change volumes, oil and

For the report sheet, refer to “Basic service” page 4

2 The parking brake on vehicles with drum brakes

• Vehicles with central lubrication:

Note: It is of extreme importance that the correct

3 Changing engine oil and filters

• Remove any sound baffles under the engine.

• Clean around the drain plug.

• Remove the drain plug. Tighten the drain plug using

T1007362 • Drain the oil.

• Clean the filters and filter brackets externally to prevent

• Remove the existing oil filters with oil filter tool

• Apply a thin film of oil to the rubber seals on the

• Then turn an additional 3/4 to one complete turn (or as

• Check the oil filler system and dipstick.

• Refit any sound baffles under the engine.

For information concerning oil grades, oil change volumes

Checking the oil level

• Start the engine and check for oil leaks.

4 Checking the oil level in the

Front axle wheel gears

The front axle must be raised.

• Clean around the level/filler plugs (A) for the wheel

• Turn the wheel so that the level mark by the level/filler

T1007657 • Top up with oil if necessary.

• Refit the level/filler plugs for the wheel gears. If the

Front axle differential carrier

• Clean around the level/filler plug (A).

• Top up with oil if necessary.

For information about restoring the oil level in the driving

• Refit the level/filler plug (A).