vnl volvo operators manual maintenance and engine

8/8/2019 VNL VOLVO Operators Manual Maintenance and Engine

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Operator's ManualMaintenance and Engine


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

NOTE! It is important that this manual stays with the vehicle when itis sold. Important safety information must be passed on to the new cus-tomer. The service information contained in this manual gives the

owner important information about maintaining the vehicle but is notintended as a substitute for the Preventive Maintenance Service Manualand must not be regarded as such.

The National Highway Traffic Safety Administration (NHTSA) andVolvo Trucks North America, Inc. should be informed immediately ifyou believe that the vehicle has a defect that could cause a crash, in-

jury or death.

Contact NHTSA by calling the Auto Safety Hotline at 1 (800) 4249393 (or 3660123 in the Washington, DC area) or by writing to:

NHTSA, U.S. Department of Transportation, Washington, DC 20590.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-20 154722

2001 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced,stored in retrieval system, or transmitted in any forms by any means,electronic, mechanical, photocopying, recording or otherwise, withoutthe prior written permission of Volvo Trucks North America, Inc..


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Contents

General Information ............................................................................ 1

Information For the Owner ................................................................. 1

Safety Information ............................................................................... 3

Proper Maintenance Procedure ........................................................... 3

Injury Prevention ................................................................................. 6

Engine Damage Prevention ............................................................... 15

Electric System Damage Prevention ................................................ 17

Speed Restrictive Tires ..................................................................... 19

Reporting Safety Defects .................................................................. 20

General Engine Design Information ............................................... 21

Engine Overview D7 ......................................................................... 21

Engine Compartment Overview D7 ................................................. 23

Engine Overview, D12 ...................................................................... 25

Engine Compartment Overview, D12 .............................................. 27

Engine Features ................................................................................. 29

VECTRO II Customer Parameter Values, D7 .................................. 30

VECTRO II Customer Parameter Values, D12 ................................ 31

Engine Variants, D7 .......................................................................... 32

Engine Variants, D12 ........................................................................ 33

Engine Data ....................................................................................... 34

Engine Storage ................................................................................... 35

Engine Storage .................................................................................. 35

Cooling System ................................................................................... 37

General Coolant Information ............................................................ 37

Water Specification ........................................................................... 44

Additives ............................................................................................ 45

Antifreeze .......................................................................................... 46

Fuel System ........................................................................................ 54

Fuel Safety Reminders ...................................................................... 54

Diesel Fuel Specification .................................................................. 55

Fuel Additives ................................................................................... 59

Alternative Fuels ............................................................................... 62

Oil System ........................................................................................... 63


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Engine Oil ......................................................................................... 63

Oil Sampling ..................................................................................... 74

Short-Haul Service Schedule for VN-Series ................................... 78

General and Check-Charts ................................................................ 78

Maintenance Categories .................................................................... 82

Long-Haul Service Schedule for VN-Series ................................... 88

General and Check-Charts ................................................................ 88

Maintenance ....................................................................................... 91

Engine Maintenance .......................................................................... 91

Flushing Cooling System, D7 ........................................................ 117

Flushing Cooling System, D12 ...................................................... 120

Turbo and Charge Air Cooler ......................................................... 122

Replacing Fuel Filters, Volvo Engines ........................................... 124

Fuel System Service ....................................................................... 125

Transmission and Rear Axle Maintenance ..................................... 135

Steering and Brakes Maintenance .................................................. 138

Electrical System Maintenance ....................................................... 144

Tires, Wheels and Hub Maintenance ............................................. 146

Chassis Maintenance ....................................................................... 150

Cab Maintenance ............................................................................. 152

Lubrication, VN .............................................................................. 157Viscosity and Capacity Tables ........................................................ 161

Literature .......................................................................................... 170

Service Assistance and Manuals .................................................... 170

Service Charts .................................................................................. 172

Scheduled Services ......................................................................... 172

Repair Record ................................................................................. 175

Tire Record ...................................................................................... 181

Fuel and Oil Record ....................................................................... 192

Index .................................................................................................. 199


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Warning Label Information

IMPORTANT

Before driving this vehicle, be certain that you have read and thatyou fully understand each and every step of the driving and han-dling information in this Maintenance Manual. Be certain that youfully understand and follow all safety warnings before servicing anycomponent on this vehicle.

IT IS IMPORTANT THAT THE FOLLOW-

ING INFORMATION CONCERNINGLABELS BE READ, UNDERSTOODAND ALWAYS FOLLOWED.

The following types of labels are usedthroughout this manual:

NOTE! A note defines an operating proce-

dure, practice, condition, etc., which isessential to proper operation of the vehicle.

CAUTION

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

with a black border.

WARNING

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

with a black border.

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


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General Information 1

Information For the OwnerIf there are questions on the maintenanceand performance of your vehicle, please

discuss them with your Volvo Truck dealer.Your authorized dealer is required to havetrained mechanics, special tools and spareparts to fully service your vehicle. Ifnecessary, your dealer will contact the man-ufacturer for assistance.

In addition to this Maintenance Manual,there may be additional instruc-tion/operators manuals supplied bycomponent manufacturers. These manuals

are placed in the Owners Package andplaced in the cab. Be sure to read all themanuals thoroughly before operating thevehicle.

Also, various safety labels may be placedon components by the component manufac-turer. Be sure to read and follow theselabels to prevent damage to the vehicle,personal injury or even death.

Information in this manual refers to Volvocomponents and Volvo drivetrain. Informa-tion concerning non-Volvo engines and/ordrivetrains can be obtained by contactingthe respective manufacturer.

Establish a Preventive Maintenance Pro-gram with the help of your local Volvo

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

NOTE! Federal law requires manufacturersto notify owners of its products in the eventof a Federal Motor Vehicle Safety Standardor if a safety related defect is discovered. Ifyou are not the original owner of this vehi-cle, please notify us about the change inownership at the address below or throughan authorized Volvo Truck dealer. This isthe only way we will be able to contactyou if necessary.

Volvo Trucks North America, Inc.

P. O. Box 26115

Greensboro, NC 274026115

United States of America


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2 General Information

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

This Maintenance Manual covers all Volvovehicles manufactured by Volvo TrucksNorth America, Inc., including the wholechassis and all Volvo manufactured compo-nents. Specific maintenance information onvendor components, manufactured by, forexample: Cummins, Detroit Diesel, Fuller,Meritor, etc., see the respective manufac-turers service and maintenance literature.

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

All information, illustrations and specifica-

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

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


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Safety Information 3

Proper Maintenance Procedure

During MaintenanceWhenever performing maintenance or re-

pair, attach a DO NOT OPERATE orsimilar warning label or sign to the ignitionkey or prominently displayed on the instru-ment panel.

Do not allow unauthorized personnel on,

around or in the vehicle when mainte-

nance or repair is being performed.

Before working on a vehicle, set theparking brakes, place the transmission inneutral, and block the wheels. Failure todo so can result in unexpected vehiclemovement and can cause serious per-sonal injury or death.

WARNING

Do not attempt to repair or service thisvehicle without having sufficient train-ing, correct service literature and theproper tools. Failure to follow this couldlead to personal injury or making yourvehicle unsafe.

WARNING

Diesel engine exhaust and some of itsconstituents are known to the state ofCalifornia to cause cancer, birth defectsand other reproductive harm.

Do not breathe the engine exhaust gas. Itcontains carbon monoxide, which has nocolor or odor. Carbon monoxide is adangerous gas which can cause uncon-sciousness and death.

When operating the engine in an en-closed area, vent the exhaust to theoutside.

Before servicing your vehicle, applythe parking brakes and adequatelychock the wheels in order to preventunintended vehicle movement. If theservice procedure requires the parkingbrakes to be released recheck to en-sure that the wheels are adequatelychocked to prevent all forward and/orrearward movement.

Do not use combustible substances inor around the engine either during re-pair or maintenance or when runningthe engine.

Never operate the engine in an areawhere hydrocarbon vapors (gasoline, for

example) are present or are suspected tobe present. Hydrocarbon vapors can en-ter the air intake and overspeed theengine, causing severe engine damageand/or an explosion and fire. Seriouspersonal injury or death could occur.


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4 Safety Information

Do not wear loose clothing or jewelrythat can catch or get snagged by partsor moving components on the engine.Also wear all protective equipment re-quired by the job conditions, such asprotective glasses, hearing protection,etc.

Make certain that all protective coversand guards are in place and secured.

Never put maintenance fluids intoglass containers since glass containerscan break.

Report all problems in a timely man-ner before they threaten the safety ofoperating the vehicle.

Do not work on the engine while it isrunning.

Tag the vehicle with the DO NOTOPERATE sign. Make sure other pro-tective locks and covers are in theirproper place.

Disconnect the batteries wheneverperforming any repairs or before ser-vicing the electrical system.

DO NOT use high amperage elec-tronic starting devices for

jump-starting the engine. Rely on con-ventional battery charging for chargingthe batteries or jump-start with thehelp of a start battery.

DO NOT attempt repairs you do notunderstand or have the proper tools for.

When starting an engine after repairshave been made to the fuel or injectionsystem, prepare equipment for shuttingoff the engine intake air and/or fuelsupply (to stop the engine), in casethere is an overspeed on start-up.

Start the engine only from the driverseat. Never operate the starter motoracross the starter terminals or the bat-teries as this could by-pass the engineneutral-start system as well as causingdamage to the electrical or electronicsystems.

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


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Compressed Air and Water

WARNING

Compressed air can cause personal in-jury. When using compressed air forcleaning, wear a protective face shield,protective clothing and protective shoes.Pressurized water could cause particlesand/or hot water to be sprayed in yourdirection and cause personal injury. Themaximum air pressure must be below30 psi (200 kPa) for cleaning purposes.

Asbestos InformationNOTE! The Volvo engine and its replace-ment parts shipped from the factory areasbestos free. Volvo recommends the use ofonly genuine Volvo spare parts.Never use any parts that contain or arethought to contain asbestos. Exposure to as-bestos fibers can create serious health risks,including death.

Fluid Penetration

WARNING

Always use a piece of paper orcardboard when checking for a leak. Es-

caping fluid under high pressure, even apin-hole sized leak, can penetrate bodytissue, causing serious injury.


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Injury Prevention

Burn Prevention

Engine Parts

WARNING

Hot engine. Keep yourself clear of allhot engine parts and/or fluids. A hot en-gine and/or fluids can cause seriousburns.

Do not touch any part of the engine whileit is hot. Allow the engine to cool beforeany repair or maintenance is performed on

the engine.

Do not raise the engine hood or cab if yousee or hear steam or coolant escaping fromthe engine compartment. Wait until steamor coolant cannot be seen or heard beforeraising the hood or cab.

Do not remove the coolant fill cap if thecoolant in the surge tank is boiling. Also,do not remove the cap while the engine and

radiator are still hot. Scalding fluid andsteam may be blown out under pressure ifthe cap is taken off too soon.

Relieve all pressure in air, oil, fuel or cool-ing systems before any lines, fittings orrelated items are disconnected or removed.

W0001525


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CoolantTo prevent personal injury, do not climb upon the engine to remove the filler cap. Usea suitable, properly positioned ladder toreach up to the cap. At normal operatingtemperature, the engine coolant is very hotand under pressure. If pressure is relievedrapidly in a hot cooling system, the hotcoolant can turn into steam. Any contactwith hot coolant or steam can cause severeburns. The radiator and all heating systemand radiator lines and hoses contain hotcoolant.

WARNING

Under some conditions, the ethyleneglycol in antifreeze can be combustible.To help avoid being burned when addingcoolant, do not spill coolant on the ex-haust system or engine parts that may behot.

Verify coolant level only by the markings

on the expansion tank. Open the filler caponly after the engine has been stopped andcooled down. Remove the filler cap slowlyto relieve pressure.

W0001527


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Oils

WARNING

Hot engine. Keep yourself clear of allhot engine parts and/or fluids. A hot en-gine and/or fluids can cause seriousburns.

Hot oil can cause severe burns. Do not al-low hot oil to contact the skin. Whenchanging oil, wear protective gloves.

Batteries

WARNING

Always wear eye protection when work-ing around batteries to prevent the riskof injury due to contact with sulfuricacid or an explosion.

WARNING

Battery posts, terminals and relatedaccessories contain lead and lead com-pounds, chemicals known to the State ofCalifornia to cause cancer and reproduc-tive harm. Wash hands after handling.

Battery electrolyte contains acid and cancause injury. Avoid contact with the skinand eyes. Wash hands after touching batter-ies and connectors. Use of gloves isrecommended. Always wear protectiveglasses when working with batteries.


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Fire or Explosion Prevention

The diesel engine will operate on anyfuel which enters the cylinder, whether itis from the injectors or from the air in-take system. Therefore, if any solvent isused to flush out the air cleaner element,the engine may overspeed duringstart-up. Engine damage and severeinjury and/or death from burns or explo-sion can occur.

The engine should not be operated in anarea where combustible gases are suspectedto be in the air. These could be drawn intothe engine through the engine air intakesystem and could cause the engine to over-speed with possible serious damage to theengine and bodily injury or propertydamage.

W0001526

Excessive heat may cause the pressur-ized components of the air conditionedsystem to explode. Never weld, solder,steam clean or use a gas torch near anypart of the air conditioning system. Se-vere injury or death may occur from anexplosion.

Do not pressure or leak test R134a refriger-ant for air conditioning or servicingequipment using compressed air. Somemixtures of air and R134a refrigerant havebeen shown to be combustible at elevatedpressures. These mixtures, if ignited, cancause injury or property damage. Consultthe R134a Material Safety Data Sheet(MSDS) for additional information.


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To avoid potential fire hazard, do notservice any part of the fuel system whilesmoking or in the presence of flames,sparks or hot surfaces, or when workingon an operating engine. Failure to followthese precautions can result in fire. Toguard against burns from direct contactwith hot fuel, wear adequate protectiveclothing (face shield, heavy gloves andapron, etc.) when working on a hot en-

gine.

All fuels, most lubricants and some coolantmixtures are flammable. Diesel fuel isflammable. Gasoline is flammable. Themixture of diesel and gasoline fumes is ex-tremely explosive. Do not smoke whilerefueling or when in a refueling area.

WARNING

Do not store fuel containers in the vehi-cle. They may leak, explode and causeor feed a fire. Empty or full, theypresent a hazard that may lead to a fireand personal injury.

Keep all fuels and lubricants stored inproperly marked containers and away fromall unauthorized personnel. Store oily ragsor other flammable material in a protective

container, in a safe place. Remove allflammable material such as fuel, oil andother substances before they accumulate onthe engine. Do not expose the engine toflames, driving over burning ground, etc., ifat all possible. Do not weld or flame cut onor around pipes or tubes that containflammable fluids.

W0001527


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Exhaust heat shields may be installed toprotect oil or fuel carrying lines and pipesfrom hot exhaust parts. To protect from pipeor seal failure, install heat shields correctly.

Provide adequate and proper waste oil dis-posal. Always dispose of waste liquidsaccording to Federal and local regulations.Oil and fuel filters should be properly in-stalled and housing covers tightened to theproper torque when being changed.

Starting Aids

Do not use ether or similar starting aidsin a Volvo or any other engine with apreheater. The Volvo engine is equippedwith a preheater. Introduction of ether orother combustible material in the intakemanifold could cause a fire or explosion,resulting in personal injury or death.

DO NOT use ether or other combustiblestarting aids on engines that have a heaterelement or other heating devices installedin the intake manifold for heating intake airat cold-starts.

W0001484

Fire Extinguisher

Anytime work is being done to the fuelsystem or any other area where flammablesubstances are being used, have a fire extin-guisher available and know how to use it.Inspect and have it serviced as recom-mended on its instruction label.


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Respiratory Hazard Prevention

Do not breathe the engine exhaust gas. Itcontains carbon monoxide, which has nocolor or odor. Carbon monoxide is adangerous gas which can cause uncon-sciousness or death.

WARNING

Diesel engine exhaust and some of its

constituents are known to the state ofCalifornia to cause cancer, birth defectsand other reproductive harm.

Always work in a well ventilated space ifthe engine needs to be running and use ahose to route the exhaust to the outside.

W0001523

Poisonous Substances

Risk of poisoning. Ethylene and propy-lene glycol are toxic. To preventpersonal injury or death, do not drinkcoolant. Use proper eye and hand pro-

tection when handling. Keep coolant orconcentrated antifreeze out of reach ofchildren and animals.

Cooling system supplemental additive con-tains alkali. To prevent personal injury,avoid contact with the skin and eyes. DONOT drink coolant of any concentration.


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Crushing or Cutting Prevention

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

WARNING

Do not work near the fan with the en-gine running. The engine fan can engageat any time without warning. Anyonenear the fan when it turns on could beseriously injured. Before turning on theignition, be sure that no one is near thefan.

Support equipment and components prop-erly when working beneath them. Neverattempt adjustments while the engine is

running unless otherwise specified for theservice procedure. To help prevent an acci-dent caused by moving parts, workcarefully around them. Guards, covers andshields should be in place whenever main-tenance is not being performed. Keepobjects away from moving fan blades. Theywill throw or cut any object or tool thatfalls or is pushed into them.

Inspect the fan blade assembly before ser-

vice for cracks or loose mounting beforestarting the engine. Never stand beside arotating fan assembly, particularly at highfan speeds.

W0001524


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Wear protective glasses when striking ob-jects to avoid injury to your eyes. Chips orother debris can fly off objects that arestruck. Make sure no one can be injured byflying debris before striking any object.

W0001528

Climbing Up and Down

Always have three limbs (one foot andtwo hands or two feet and one hand) incontact with the vehicle at all timeswhen entering or exiting the cab or thearea behind the cab. Failure to followthis guideline may result in a fall thatcan cause serious personal injury ordeath.

DO NOT climb up on or jump off from theengine or stand on components that cannotsupport your weight. Use an adequate lad-der or scaffolding, suitably situated. Do notuse top of engine or cowling ledge asfoothold when reaching on top of cab.Clean steps, handholds and areas of the ve-hicle you will be working on or around.Refer to the Operators Manual for properentry and exit procedures.

Always use a three-point stance (twohands one foot or one hand two

feet) whenever climbing up or down.


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Engine Damage Prevention

Before Starting the Engine


Inspect engine for potential hazards. Make

sure all protective guards and covers areproperly installed if an engine needs to bestarted to make adjustments or checks. Tohelp prevent an accident by moving partswork carefully around them.

DO NOT disable or bypass automaticalarm/shutoff circuits. They are provided toprevent personal injury and engine damage.

The diesel engine will operate on anyfuel which enters the cylinder, whether itis from the injectors or from the air in-take system. Therefore, if any solvent isused to flush out the air cleaner element,the engine may overspeed duringstart-up. Engine damage and severeinjury and/or death from burns or explo-sion can occur.

Make provisions for shutting off the engineintake air or fuel supply to stop the engineif there is an overspeed on start-up afterperforming repair or maintenance on it.

Always consult the proper Volvo ServiceManual before any repair is attempted.


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Engine StartingDO NOT start the engine or move any ofthe controls or disengage the parking brakeif the warning tag DO NOT OPERATE is

attached to the ignition key or located onthe dash. Check with the person who at-tached the tag before starting.

Make sure no one is working on or close tothe engine or components driven by the en-gine before starting it. Always make aninspection of the engine before and afterstarting.

Diesel engine exhaust contains products of

combustion which may be harmful to yourhealth. Always start and operate the enginein a well-ventilated area, and if in an en-closed area, vent the exhaust to the outside.

Start the engine only from the driver seat inthe cab. Never start the engine by shortingacross the starter motor terminals or batter-ies to start the engine as this could bypassthe engine neutral-start system as well asdamage the electrical and electronic sys-

tem. Always start the engine according tothe required engine starting procedure de-scribed in this operators manual to preventmajor engine component damage and per-sonal injury.

Starting Aids

Do not use ether or similar starting aidsin a Volvo or any other engine with apreheater. The Volvo engine is equippedwith a preheater. Introduction of ether orother combustible material in the intakemanifold could cause a fire or explosion,resulting in personal injury or death.

W0001484


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Electric System Damage Prevention

Electric and Electronic Systems

Never disconnect any charging unit circuitor battery circuit cable from the batterywhen the charging unit is operating. Aspark can cause the flammable vapor mix-ture of hydrogen and oxygen to explode.

To prevent potential sparks from ignitingcombustible gases produced by some bat-teries, attach the negative (-) terminal lastwhen hooking up and remove the negativeterminal first after the engine has started.

Check regularly around the engine and en-gine compartment for loose or frayed wires.Have all loose or frayed electrical wirestightened, repaired or replaced before oper-ating the vehicle.

W0001526

WARNING

Always wear eye protection when work-ing around batteries to prevent the riskof injury due to contact with sulfuricacid or an explosion.

Grounding PracticesProper grounding for vehicle and engineelectrical and electronic systems is neces-

sary for proper vehicle and engineperformance and reliability. Impropergrounding will result in uncontrolled andunreliable electrical paths.

Uncontrolled engine electrical circuit pathscan result in damage to main bearings,crankshaft journals surfaces and aluminumcomponents. Uncontrolled electrical circuitpaths can also cause electrical noise whichmay degrade vehicle and radio performance.

Operating engines without the engine-to-frame ground strap installed can causedamage to the engine. To prevent electricaldischarge damage, check to make sure theengines electrical system has an engine-to-frame ground strap. All ground connectionsshould be tight and free of corrosion.


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Electronic Engine Control SystemTampering with the electronic system in-stallation can be dangerous and could resultin personal injury or death and/or enginedamage. It is very important to take theproper precautions with the electrical andelectronic system when charging the batter-ies, jump-starting or performing electricwelding on the vehicle. See the vehicle Op-erators Manual for correct procedures.

The Volvo D12 engine uses high voltageto the electronic unit injectors. DO NOTcome in contact with the unit injectorterminals while the engine is running.An electric shock can cause an involun-tary muscle spasm and cause balanceloss and falls leading to severe personalinjury or death.

This engine is equipped with monitoring

features that may cause reduced power orshutdown under certain conditions. Thepower output, monitoring and idling fea-tures can only be programmed and/orchanged with electronic service tools andpasswords.

Certain features, such as low oil pressure,high coolant temperature or low coolantlevel could cause the engine power and/orvehicle speed to be limited and the engine

may also shut down. The shutdown willtake approximately 30 seconds from thetime the warning feature is activated. Seethe vehicle Operators Manual for moreinformation.

W0001522


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Speed Restrictive TiresWhen a truck is equipped with Speed Re-strictive Tires it is extremely important thetruck should not be operated in excess of

the indicated speeds. If your truck isequipped with such tires, the speed restric-tions will be stated on the sidewall of thetires. The operator of this vehicle is urgedto check the tires of the truck to determineif there are any limitations.

Operating a vehicle equipped with SpeedRestrictive Tires in excess of their statedrating may result in tread separationand/or blowout resulting in the loss ofsteering control and possible crash. Seri-ous personal injury or death could occur.Always maintain proper air pressure andnever exceed the tire ratings.


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Reporting Safety Defects

USAThe National Highway Traffic Safety Ad-ministration (NHTSA) and Volvo Trucks

North America should be informed imme-diately if you believe that the vehicle has adefect that could cause a crash, injury ordeath.

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

1 (800) 424-9393

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

1 (905) 795-1555

MexicoVolvo Trucks of Mexico, S.A. de C.V.should be informed immediately if you be-lieve the vehicle has a defect that couldcause a crash, injury or death. Contact

Volvo Trucks de Mexico by calling 91 (5)2593011 or by writing to: Volvo Trucksde Mexico, S.A. de C.V., Prol. Paseo de laReforma 600, 1er. Piso 121, Col. SantaFe Pea Blanca, C.P. 01210, Mxico, D.F.

01 (800) 90 94 900


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General Engine Design Information 21

Engine Overview D7

W2002703

1. Fuel filters (secondary)

2. Turbocharger

3. Exhaust pressure governor (EPG)

4. Coolant drain connection

5. Coolant filter

6. Electronic injection pump

7. Hand fuel primer pump


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22 General Engine Design Information

W2003664

8. Engine electronic control unit(EECU)

9. Oil fill cap

10. Oil dipstick

11. By-pass oil filter

12. Full-flow oil filter

13. Starter motor


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Engine Compartment Overview D7

W2002695

1. Electronic injection pump

2. Exhaust pressure governor (EPG)

3. Fuel filters (secondary)

4. Inlet from charge air cooler

5. Coolant surge tank

6. Fuel filter (primary)(location depends on model)

7. Oil fill cap(hidden from view)


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W2003643

8. Engine air filter

9. Air filter restriction gauge

10. Intake air heater

11. Oil dipstick

12. Air compressor

13. Outlet from charge air cooler


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Engine Overview, D12

W0001846

1. Oil Fill Cap

2. Starter Motor

3. Electronic Control Unit (ECU)

4. Fuel Filter (secondary)

5. Oil dipstick (Earlier model D12)


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W0001847

9. Coolant Drain Connection

10. Exhaust Pressure Governor(EPG)

11. EPG Air Valve

12. Turbocharger

13. By-Pass Oil Filter

14. Full-Flow Oil Filters

15. Air Compressor

16. Coolant Filter

17. Coolant Radiator

18. Charge Air Cooler


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Engine Compartment Overview, D12

W2003417

1. Oil Fill Cap

2. Intake Air Heater

3. Engine Electronic Control Unit(EECU)

4. Coolant Surge Tank

5. Outlet From Charge Air Cooler


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W2003420

6. Engine Air Filter

7. Coolant Fill Cap

8. Radiator

9. Primary Fuel Filter

10. Oil Dip Stick (Latest modelD12)

11. Turbocharger (Hidden behindEngine Air Filter)


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Engine Features

Feature Benefit

VECTRO II - Volvo EngineElectronics System

Engine Brake Control (D12)

Differentiated Speed Control Road Speed Limiter PTO Speed Setting Cruise Control Idle Speed Setting Idle Timeout

VECTRO II Diagnostics Ease of Troubleshooting

Air-to-Air Charge Air Cooler Superior Fuel Economy Peak Performance

Low Process Temperature Two-Piece Piston and Optimized

Compression Ratio (D12) Minimum White Smoke Low Internal Friction

Standard Exhaust Brake Efficient Braking on Grades Superior Temperature Control at Idle Quick Warm-Up

Optional Volvo Engine Brake (VEB)(only D12)

Exceptional Engine Braking Even atLow Engine Speed

Optional Pre-Heater Element

Excellent Startability to as Low as

-15

F (-25

C)

Minimum Smoke and Odor After Start No Fuel Dilution of Oil in Cylinder

Due to Complete Combustion

Less Engine Wear

Cylinder Liners with Plateau Honing Optimized Oil Consumption

Engine-Mounted Fan Ring Efficient Cooling with Low ParasiticLosses

Electronically Controlled Fuel Injection

Precise Control of Combustion

Centrally Located Vertical UnitInjectors

Maximum Fuel Efficiency

Engine-Driven Power Take-Off Clutch Independent PTO


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VECTRO II Customer Parameter Values, D7

Parameter Default

Value

Minimum

Value

Maximum

Value

PTO:

Maximum engine speed, r/min Resume speed

2500800

Low IdleLow Idle

High IdleHigh Idle

Road Speed Limit (RSL):

Value RSL (technical), mph (km/h) Printout RSL value, mph (km/h)

87 (140)87 (140)

30 (48)30 (48)

87 (140)87 (140)

Cruise Control (CC):

CC enable (yes/no) Maximum Vehicle Speed, mph (km/h) Minimum Vehicle Speed, mph (km/h)

Yes

87 (140)30 (48)

-

30 (48)30 (48)

-

RSLRSL

Differentiated Speed Limiter:

Yes/No Transmission With Overdrive (yes/no)

NoNo

--

--

External Engine Protection:

Yes/No Yes - -

Standstill Maximum Engine Speed:

Maximum Engine Speed, r/min High Idle 2500 High Idle

NOTE! This parameter listing is not com-plete. Contact your Volvo Truck dealer fora complete listing.

Customer Parameters can be changed witha VCADS Pro tool, available at your VolvoTruck dealer.


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VECTRO II Customer Parameter Values, D12

Parameter Default

Value

Minimum

Value

Maximum

Value

PTO:

Maximum engine speed, r/min Resume speed

1200800

Low IdleLow Idle

High IdleHigh Idle

Road Speed Limit (RSL):

Value RSL (technical), mph (km/h) Printout RSL value, mph (km/h)

87 (140)87 (140)

30 (48)30 (48)

87 (140)87 (140)

Cruise Control (CC):

CC enable (yes/no) Maximum Vehicle Speed, mph (km/h) Minimum Vehicle Speed, mph (km/h)

Yes

87 (140)30 (48)

-

30 (48)30 (48)

-

RSLRSL

Differentiated Speed Limiter:

Yes/No Transmission with Overdrive (yes/no)

NoNo

--

--

Idle Timeout:

Yes/No Time Before Shutdown (if yes), minutes

No5

-1

-40

Standstill Maximum Engine Speed:

Maximum Engine Speed, r/min High Idle 1200 High Idle

NOTE! This parameter listing is not com-plete. Contact your Volvo Truck dealer fora complete listing.

Customer Parameters can be changed witha VCADS Pro tool, available at your VolvoTruck dealer.


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Engine Variants, D7

Power Output Options

D7C-275 D7C-300

Output, net1, @ 2,200 r/min 275 hp(205 kW)

300 hp

(224 kW)

Torque, net1, @ 1,400 r/min 800 lb-ft(1 085 Nm)

950 lb-ft

(1 288 Nm)

Governed speed 2,200 r/min 2,200 r/min

1Net output according to ISO 1585 and SAE J1349.

Engine Standard Equipment

Air-to-air charge air cooler

Primary fuel filter and Volvo spin-onsecondary fuel filters

Exhaust pressure governor (EPG)

Electronically controlled fuel injection

One Volvo full-flow and one Volvo by-pass oil filters

Electronic engine diagnostics system

Intake air preheater element

Thermostatically controlled fan

100 Ampere alternator

Side mount oil fill tube (WX only)

Base Warranty: 2 years or 250,000miles; parts and labor (For coveredcomponents, see the warranty certifi-cate)

Engine Optional Equipment

Engine block heater for coolant

Engine oil pan heater

Side-mounted oil fill tube (WG)

Alternators from 85 to 145 Ampere


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Engine Variants, D12

Power Output Options

D12C-345 D12C-385 D12C-425 D12C-465

Output, net1, @ 1700 r/min 345 hp(254 kW)

385 hp

(283 kW)

425 hp

(317 kW)

465 hp

(338 kW)

Torque, net1, @1100 -1200r/min

1350 lb-ft

(1830 Nm)

1450 lb-ft

(1965 Nm)

1550 lb-ft

(2100 Nm)

1650 lb-ft

(2236

Nm)

Governed speed 1900 r/min 1900 r/min 1900 r/min 1900r/min

1Net output according to ISO 1585 and SAE J1349.

Engine Standard Equipment

Air-to-air charge air cooler

Primary fuel filter and Volvo spin-onsecondary fuel filter

Exhaust pressure governor (EPG)

Electronically controlled fuel injection

Double Volvo full-flow and one Volvoby-pass oil filters

Thermostatically controlled oil cooler

Electronically controlled unit injectors

Overhead camshaft

Electronic engine diagnostics system

On/off fan clutch

110 Ampere alternator

Base Warranty: 2 years or 250,000miles; parts and labor (For coveredcomponents, see the warranty certifi-cate)

Engine Optional Equipment Volvo Engine Brake 350 hp brak-

ing power @ 2 300 r/min.

Engine direct-mounted PTO outputup to 60 hp or 300 lb-ft

Intake air preheater element

Engine block heater for coolant

Engine oil pan heater

Side-mounted oil fill tube

85 or 135 Ampere alternator

Thermostatically controlled fan


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Engine Data

Fill in the blanks for future reference:

Vehicle Identification Number (VIN) [ ................................................................................ ]

Engine Model [ ..................................................................................................................... ]

Engine Serial Number [ ....................................................................................................... ]

Engine Power Output [ ......................................................................................................... ]

Engine Low Idle Speed [ ..................................................................................................... ]

Engine Full Load Speed [ .................................................................................................... ]

Engine Full Torque [ ............................................................................................................ ]

Primary Fuel Filter P/N [ ..................................................................................................... ]

Secondary Fuel Filter P/N [ ................................................................................................. ]

Oil Filter P/N, Full Flow [ ................................................................................................... ]

Oil Filter P/N, By-pass [ ...................................................................................................... ]

Air Cleaner Element P/N [ .................................................................................................. ]

Coolant Filter P/N [ .............................................................................................................. ]

Fan Drive Belt Set P/N [ ...................................................................................................... ]

Alternator Belt P/N [ ............................................................................................................ ]


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Engine Storage 35

Engine StorageIf the vehicle should be parked for a period(over 30 days), make it is protected as fol-

lows:

1 Drain the engine of its used oil.

2 Fill up to the proper level with oil ofthe recommended quality and viscos-ity.

3 Fill up the fuel tanks with the recom-mended grade of fuel.

4 Run the engine for two minutes around

1000 r/min. Shut the engine down. Donot drain the oil after this run.

5 Check the engine air filter and, if nec-essary, change it.

6 Check the coolant for proper levels ofantifreeze and inhibitor (SCA) protec-tion. Service as necessary.

7 Clean the exterior of the engine.

8 Seal all engine openings using a wa-terproof, vaporproof and strong tape.

To return an engine preserved in this man-ner can be done in a short time by removingthe seals and checking all engine fluids:coolant, fuel, crankcase oil. Also check allother component fluid levels on the vehicle.


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36 Engine Storage

Starting Engine After an Extended Shutdown


If an engine has been sitting unused formore than a week or if an oil change hasbeen performed, it is recommended that the

oil pressure is established before startingthe engine. This can be done by crankingthe engine without fuel delivered to thecylinders. Let an experienced techniciancarry out the following:

1 Separate the in-line fuse feeding theengine electronic control unit. Thefuse is located in the battery box.

2 Use the starter to turn the engine overuntil the oil pressure registers on the

oil gauge.

CAUTION

Do not crank the engine for morethan 30 seconds at a time; wait twominutes after each try to allow thestarter to cool. Failure to followthese instructions could causestarter damage.

3 Install the fuse.4 Start the engine.

NOTE! This procedure will load a fault inthe diagnostic message display but will notinterfere with running the engine.

W3002417

VN-series fuse location


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Cooling System 37

General Coolant Information

GeneralDo not raise the engine hood or cab if you

see or hear steam or coolant escaping fromthe engine compartment. Wait until steamor coolant cannot be seen or heard beforeraising the hood or cab.

Do not remove the coolant fill cap if thecoolant in the surge tank is boiling. Also,do not remove the cap while the engine andradiator are still hot. Scalding fluid andsteam may be blown out under pressure ifthe cap is taken off too soon.

W2002056

WARNING

Hot engine! Keep yourself clear of allmoving parts or hot engine parts, ex-haust gases, and/or fluids. A hot engine,exhaust, and/or fluids can cause burns.


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38 Cooling System

Many engine failures can be traced back toa problem in the cooling system. Alwaysmake sure that the coolant level is abovethe min. mark on the surge tank. If thecoolant level is allowed to go below thebottom of the tank, there is the risk of theengine shutting down. See the OperatorsManual for more information on the warn-ing functions. See page 118 or page 120 forinformation on how to change the coolant.

Risk of poisoning. Ethylene and propy-

lene glycol are very toxic. To preventpersonal injury or death, do not drinkcoolant. Use proper eye and hand pro-tection when handling. Keep coolant orconcentrated antifreeze out of reachfrom children and animals.

NOTE! Always dispose of coolant accord-ing to Federal or local regulations. Take allused coolant to a recycling or waste collec-tion center.

W2002049


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Cooling System 39

Recommended coolant mixture is a 50/50mixture of antifreeze and clean water.Never run the engine with only water. Re-gardless of the season, the coolant shouldalways contain at least 40 to 60 percentethylene glycol (antifreeze). The antifreezealso contains anti-corrosion agents that thecooling system needs to stay functional.

NOTE! Do not use a winterfront for thecooling system. See the Operators Manual,Engine Start and Operation, for more infor-mation.

NOTE! Do not mix regular and extendedlife antifreeze. This may result in reducedengine life.

Engine design requires the thermostat inthe engine during summer and winter. Cor-rect engine temperature should be aminimum of 165 F (75 C) with a properlyfunctioning thermostat.

WARNING

Under some conditions, the ethyleneglycol in antifreeze can be combustible.To help avoiding being burned whenadding coolant, do not spill coolant onthe exhaust system or engine parts thatmay be hot.

Do not add cold coolant to an overheatedengine because a cracked head and blockmay result.

W2003082


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40 Cooling System

Keep the radiator (including charge aircooler) and the frontal area free from bugs,dirt, leaves, etc. (see page 123 for cleaninginformation). Always keep the coolant levelabove the min. mark on the coolant expan-sion tank.

Inspection of the whole cooling system isimportant. Check for swollen or deterio-rated heater and radiator hoses, loose hoseclamps and connections, and radiator leaks.

WARNING

Do not work near the fan with the en-

gine running. The engine fan can engageat any time without warning. Anyonenear the fan when it turns on could beseriously injured. Before turning on theignition, be sure that no one is near thefan.

W2002049


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Cooling System 41

W2002697

1. Thermostat Housing2. Radiator3. Surge Tank4. Coolant Cap

5. Level Sensor6. Heater Element7. Coolant Filter8. Coolant Pump

Risk of poisoning. Ethylene and propy-lene glycol are toxic. To preventpersonal injury or death, do not drinkcoolant. Use proper eye and hand pro-tection when handling. Keep coolant orconcentrated antifreeze out of reach ofchildren and animals.

WARNING

Never add coolant to a hot or overheatedengine. Engine damage can result, andscalding steam or liquid can cause seri-ous personal injury.

A well functioning and maintained coolingsystem is as important to the engine as per-forming regular oil changes or using goodfuel. To get the best result it is very impor-tant to use quality products and to servicethe system at the right intervals. Pleaseread this section carefully.

The cooling system consists of a liquid thatis pumped by a gear driven coolant pumpthat keeps the flow through the engine tothe radiator. The radiator gives off heat tothe air as it passes through and air flow ishelped by the engine fan. For a quickwarm-up of the engine, a thermostat regu-lates the flow of coolant.


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42 Cooling System

Coolant is made up of a mixture of cleanwater and antifreeze. This mixture shouldnever be less than 40% antifreeze and 60%clean water or more than 60% antifreezeand 40% clean water. Mix the antifreeze/water mixture to the required concentrationbefore adding to the cooling system.

NOTE! Do not mix different products,such as regular antifreeze and extended lifeantifreeze.

NOTE! Volvo Trucks North America, Inc.does not recommend the use of antifreezebased on propylene glycol.

W2003082

Coolant, consisting of an antifreeze solu-tion in water, should be used year-round toprovide freeze and boil-over protection aswell as providing a stable environment forseals and hoses. The solution needs to betested for proper additive levels at regularintervals (see page 49 for testing SCA lev-els), unless extended life antifreeze is used.Adjust additive concentration if not at the

proper levels.NOTE! Do not use antifreeze formulatedfor automobile gasoline engines. Thesehave a very high silicate content that willclog the radiator and leave unwanted de-posits in the engine.


48/209


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44 Cooling System

Water Specification

CAUTION

Volvo Trucks North America, Inc. doesnot recommend using plain water in thecooling system. Water alone is corrosiveat engine operating temperatures anddoes not provide adequate boiling pro-tection. The water may cause corrosionand cavitation problems in engine andradiator, and the boiling point of thecoolant is lowered compared with an an-tifreeze/water mixture. The warranty is

not valid when using only water in thecooling system.

Use clean water in the coolant mixture. DONOT use hard tap water or salt softened tapwater in the cooling system. If clean wateris not available, using distilled water isideal. Water specification should be:

Parts per

Million

Grains per

GallonChlorides, maximum 40 2.5

Sulfates, maximum 100 5.8

Silica, maximum 20 1.17

Iron, maximum 0.10 0.0058

Manganese, maximum 0.05 0.0029

Total dissolved solids, maximum 340 20

Total hardness, maximum 170 10

pH value 5.5 to 9

If you are not sure of the quality of the wa-ter in your area, contact your Volvo Truckdealer, your local water department, agri-cultural agent or an independent laboratoryto analyze the water.


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Cooling System 45

AdditivesAdditives are part of most antifreeze andshould be tested for and added to all

coolant mixtures using normal antifreeze. Ifextended life coolant is used, the additivesare in the product when mixed. Both typesneed to have additives added to them aftera time.

Additives help prevent rust, scale and min-eral deposits from forming. Additives alsoprotect metals from corrosion, prevent wa-ter pump and cylinder liner cavitation andcontain anti-foaming agents. Additives aredepleted during normal engine operationand need to be replaced. For normalcoolant mixture, this means the addition ofSupplemental Coolant Additives (SCA) atany time the additive goes below the rec-ommended level. For extended life coolantmixture, this means an extender packageadded halfway through the coolant lifetime.

Nitrites or nitrite and molybdate additivesprotect the cylinder liner from cavitationerosion. Nitrites deplete over time, creatingthe need for SCAs or extender. Othercoolant additives also deplete and need re-placement.

A very low concentration of additives inthe coolant will not provide the protectionrequired by the cooling system. A veryhigh concentration of additives in the

coolant can cause additives to solidify anddrop out of the solution, depositing insidethe cooling system or form a gel in the ra-diator. Deposits can be in the form ofsludge and scale. Deposits accumulate onhot engine surfaces, reducing the effective-ness of the cooling system or causing waterpump leaks.


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46 Cooling System

Antifreeze

General

Risk of poisoning. Ethylene and propy-lene glycol are toxic. To preventpersonal injury or death, do not drinkcoolant. Use proper eye and hand pro-tection when handling. Keep coolant orconcentrated antifreeze out of reachfrom children and animals.

WARNING

Never add coolant to a hot or overheatedengine. Engine damage can result. Allowthe engine to cool first.

CAUTIONUse of recycled antifreeze or coolant byfiltration is not approved by VolvoTrucks North America, Inc. If the recy-cled antifreeze or coolant has beenpassed through a fractional distillation orsimilar process that has removed all haz-ardous and contaminating materials,including dissolved solids and acids, itwill produce a sufficient base antifreeze.Correctly inhibited to meet the ASTMD4985 standard, it can be regarded as anew coolant which is fully accepted.However, use of recycled antifreeze orcoolant by filtration may reduce enginelife.

Antifreeze additives not only protect thecooling system from freezing but also

against corrosion and cylinder liner pitting.Antifreeze typically comes in one of twoglycol types, ethylene or propylene. Propy-lene antifreeze is NOT recommended foruse in a Volvo engine. There is also regularand extended life antifreeze. If the vehicleis delivered with extended life coolant,there is a label attached to the surge tank.

NOTE! Do not mix regular and extendedlife antifreeze. Do not use extended life an-tifreeze unless it is of a type approved bythe engine manufacturer.

Regardless of the type and make, accept-able antifreeze or premixed coolant mustmeet or exceed the standards ASTM D5345 and ASTM D 4985, and be formu-lated for heavy duty diesel engines.

W2002144


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Cooling System 47

Antifreeze or premixed coolant meeting the

standards ASTM D 3306 or ASTM D 4656

are primarily for automotive gasoline en-

gines, containing high levels of silicate, and

are unacceptable for heavy duty diesel en-

gines.

Recommended antifreeze meeting theASTM D 4985 standard is a low silicateethylene glycol based antifreeze for heavyduty diesel engines. Standard antifreeze re-quires an initial charge of supplementcoolant additives (SCA) when filling newcoolant. Extended life antifreeze does notneed an initial charge.

NOTE! ASTM D 4985 requires the use ofSCA to be added to the coolant to bring itup to the recommended SCA level whenthe coolant is initially filled or replaced.

Water and antifreeze should generally befilled as a 50/50 mixture. The mixtureshould never be less than 40% antifreezeand 60% clean water or more than 60% an-

tifreeze and 40% clean water. Mix theantifreeze/water to the required concentra-tion before adding to the cooling system.The following table gives approximatefreezing protection for certain mixtures.

Freeze ProtectionDown To:

Percentage of An-tifreeze in Mixture

-13 F (-25 C) 40 %

-22 F (-30 C) 46 %

-36 F (-38 C) 54 %

-51

F (-46

C) 60 %

NOTE! 60% antifreeze in the mixture givesmaximal freeze protection. To increase theantifreeze content beyond that will only de-crease the freeze protection.

W2003082


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48 Cooling System

Regular Coolant Change IntervalReplace the coolant every 250,000 miles(400,000 km), 4,000 hours or every two

years, whichever comes first.

Coolant SCA level must be tested at leasttwice per year or whenever coolant lossoccurs. For maximum coolant system effi-ciency, test the system every 25,000 to30,000 miles (40,000 to 56,000 km) de-pending on engine oil change interval orevery 1,000 hours or maximum every 6months (whichever comes first).

The SCA level must be between 1.5 (Cum-mins: 1.2) and 3.0 SCA units per gallon(0.4 [Cummins: 0.3] and 0.8 SCA units perliter) of coolant.

NOTE! Always dispose of coolant accord-ing to Federal or local regulations. Take allused coolant to a recycling or waste collec-tion center.

Coolant Filter Change IntervalsThe charged coolant filter contains 8 unitsof SCA that are released slowly over timeto maintain the recommended level duringoperation. Change coolant filter after thefirst 30 days or 6,000 miles (10,000 km).Thereafter:

Change the coolant filter at every other oilchange when running 10,000 to 15,000mile (16,000 to 24,000 km) intervals (everyoil change when running 25,000 mile inter-vals on a D12). If the SCA level testsabove 3.0, DO NOT replace the filter.When testing indicates that the SCA levelhas dropped below 1.5 units per US gallon(0.4 units per liter) start changing the filterwith the oil changes again.

NOTE! Test the SCA level every 6 months.

WARNING

Keep yourself clear of all hot engineparts and/or fluids. A hot engine and/orfluids can cause serious burns.


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Cooling System 49

Standard Antifreeze Testing

GeneralCoolant SCA level must be tested at leasttwice per year and whenever coolant lossoccurs. For maximum coolant system effi-ciency, test the system every 25,000 to30,000 miles (40,000 to 56,000 km), de-pending on the oil change interval, or every1,000 hours or every 6 months (whichevercomes first).

Use liquid SCA and pre-charged coolantfilters to maintain a 1.5 to 3.0 SCA units

per gallon (0.4 to 0.8 units per liter) con-centration in the coolant.

W2001081

Depending on the make of antifreeze orpremixed coolant, SCAs are added or haveto be added to the system after replace-ment. The SCA level will deplete over timeso it is important that the SCA level istested regularly and maintained. The Volvopre-charged filter is designed to slowlyrelease the SCA to help maintain the rec-

ommended level during operation.

NOTE! Only change the filter after testingshows depleted SCA in the cooling system.Do not exceed the 3.0 units per gallon(0.8 units per liter) concentration. ExcessiveSCA concentration can form deposits on thehigher temperature surfaces of the coolingsystem, reducing the engines heat transfercharacteristics. Reduced heat transfer couldcause cracking of the cylinder head andother high temperature components. Exces-sive SCA concentration can also result inradiator tube blockage, overheating and/oraccelerated water pump seal wear.

W2001082

Coolant filter


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50 Cooling System

Testing ProcedureRun the engine to operating temperature.After the engine has reached operating tem-perature, move the heater controls (on dashand in sleeper) to full heat and run the en-gine for 10 more minutes.

WARNING


Shut off the engine and allow it to cool.

Test the coolant with the test kit. Dependingon the concentration of SCA in the coolant:

If the SCA concentration is below 1.5units per gallon (0.4 units per liter),replace the coolant filter and calculatethe required units of SCA to reach thedesired SCA level. See example.

Between 1.5 and 3.0 units per gallon(0.4 and 0.8 units per liter), replacethe coolant filter, P/N 3945411.

Above 3.0 units per gallon (0.8 unitsper liter). Do not replace the coolantfilter until further testing at the nextoil change indicates that the level hasdropped below 2.3 units per gallon(0.6 units per liter).

CAUTION

SCA levels deplete during normal opera-tion and when coolant is added becauseof low coolant level. SCA levels shouldbe maintained at the middle of the rec-ommended interval.Unit per gallon:1.5 LOW - 2.3 MID - 3.0 HIGHUnits per liter:0.4 LOW - 0.6 MID - 0.8 HIGH

EXAMPLE

Step 1 Desired

SCA level

2.3 units

per gallon

recom-

mended

level 1.5-

3.0 unitsper gallon

Subtract: -

Coolant

test results

1.5 units

per gallon

=

Required

SCA per

gallon

increase

0.8 units

per gallon

Step 2

Cooling

system

capacity

13 US

gallons

Use actual

system

capacity

Multiply

by:x

Required

SCA per

gallon

increase

0.8 units

per gallon

=

Total SCA

units

required

10.4 units

(11 units)

round up

to nearest

whole

number

FIND-

INGS

Use one (8 unit) filter, P/N 3945411 and

3 units liquid SCA

See Cooling System Capacity* page163 for system quantities.


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Cooling System 51

Changing from Regular to Extended Life CoolantDrain the system of old coolant and dis-pose of properly. The cooling systemshould be flushed with clean water. If sig-

nificant deposits are visible, use a reputablecommercial cooling system flush designedfor heavy duty diesel engines. For specificinformation over draining and flushing, Seepage 118 for D7 and page 120 for D12 en-gines.

1

WARNING

Do not remove the cap to thecoolant surge tank while the engineand radiator are still hot. Scaldingfluid and/or steam may be blownout under pressure if the cap istaken off too soon.

Drain the coolant into a suitablecontainer. Make sure the heater tem-perature controls and valves are open.

NOTE! Always dispose of coolant ac-cording to Federal or local regulations.Take all used coolant to a recycling orwaste collection center.

2 Flush the system with clean water toremove any settled debris.

NOTE! Keep the water pressure lowso as not to damage the tubes of the

radiator.3 Use a reputable cleaner to clean the

cooling system. Follow the recommen-dations that come with the cleaner.


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52 Cooling System

4 Drain the cleaner and flush the coolingsystem with clean water.

5 Fill the cooling system with clean wa-ter and operate the engine until the

coolant temperature has reached 120

to 150 F (50 to 65 C).

6 Drain the water and flush the coolingsystem with clean water.

7 Again, fill the cooling system withclean water and operate the engine un-til the coolant temperature has reached120 to 150 F (50 to 65 C).

8 Drain the water and flush the coolingsystem with clean water.

9 Fill the cooling system with pre-mixedExtended Life Coolant. Check thespecifications section for refill quantity.

10 Attach label P/N 3969338 to thecoolant surge tank to indicate that thesystem is now filled with ExtendedLife Coolant. The label can be or-

dered from your Volvo Truck dealerspare parts department.

NOTE! When changing over from standardto extended life antifreeze, tighten all hoseclamps and fasteners in the cooling system.Extended life coolant tends to leach out de-posited silicate and leaks may appear.

W2002144


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Cooling System 53

Extended Life Coolant Change IntervalReplace coolant every 300,000 miles(480,000 km), 6,000 hours or every fouryears, whichever comes first.

A one-time extender package must beadded to the cooling system after 150,000miles (240,000 km), 3,000 hours or twoyears, whichever comes first.

NOTE! Do not add supplement coolant

additives (SCA) to extended life coolant.

CAUTION

Extended life coolant will test as out ofadditives (SCA), but SCA should not beadded. Shortened engine life may be theresult of adding SCA.

Should the system become contaminatedwith regular coolant exceeding 10% of thesystems total capacity or if SCA is addedto the system, either drain the system andrefill with new extended life coolant or

maintain the system as for regular coolant.Continue treating with SCA and change thecoolant at the intervals recommended forregular coolant.

Coolant FilterDo not use a filter that contains SCA. In-

stead use a bypass canister or empty

filter. Replace the empty filter every

125,000 miles (200,000 km) or 2,500 h or

12 months, whichever comes first, to pre-

vent external rust damage to the filter

walls.

WARNING



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54 Fuel System

Fuel Safety Reminders

WARNING

The vapors from hot diesel fuel areflammable at high temperature. To avoidpossible personal injury and/or propertydamage from fire, stop the engine imme-diately if a fuel leak is detected. This isespecially important if the fuel is drip-ping onto hot surfaces.

To avoid potential fire hazard, do notservice any part of the fuel system whilesmoking or in the presence of flames,sparks or hot surfaces, or when workingon an operating engine. Failure to followthese precautions can result in fire, per-sonal injury or death. To guard againstburns, always wear adequate protectiveclothing (face shield, heavy gloves and

apron, etc.) when working on a hot en-gine.

A diesel engine will operate on any fuelwhich enters the cylinder, whether it isfrom the injectors or from the air intakesystem. Therefore, if any solvent is usedto flush out the air cleaner element, the

engine may overspeed during startup.Engine damage, severe injury and/ordeath from burns or explosion may oc-cur.

Do not mix gasoline or alcohol withdiesel fuel. This mixture can cause anexplosion and result in severe personalinjury or death.

Do not remove the fuel tank cap near anopen flame. Diesel fumes are com-

bustible and can cause an explosion offire resulting in severe personal injury ordeath.

WARNING

Do not store fuel containers in the vehi-cle. They may leak, explode and causeor feed a fire. Empty or full, theypresent a hazard that may lead to burns

in the event of a fire.

WARNING

To prevent buildup of potentially volatilevapors from hot fuel, keep the enginearea well ventilated during operation.


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Fuel System 55

Diesel Fuel Specification

QualityFuel quality is an important factor in ob-taining satisfactory engine performance,long engine life and acceptable exhaustemission levels. Volvo engines are designedto operate on most diesel fuels commer-cially available today. Volvo Trucks NorthAmerica, Inc. recommends the use of dieseloil fuel which meets the specificationASTM D975 (grades No. 2D andNo. 1D).

NOTE! The use of lighter fuels (grade

No. 1D) can reduce fuel economy.

The fuels used must be clean, completelydistilled, stable and non-corrosive. Alwaystry to keep the fuel tank full. Do not put al-cohol into the fuel tank. Fill the tank aftercompleting driving for the day.

NOTE! When draining the fuel tank, col-lect the waste in a fuelproof container. Takethe drained fuel and water to a recycle or

waste management center.

Open the drain at the bottom of the fueltank approximately every 30,000 miles(50,000 km) or 300 hours, to drain off anywater and/or sediment.

Yearly or at 120,000 miles (200,000 km),tighten all fuel tank mountings and brack-ets. Check all hoses, pipes and lines to andfrom the fuel tank. At the same time, in-

spect tank and connections for any signs ofleakage. Make sure that hoses and lines arenot resting on or touching shafts, couplings,hot surfaces or sharp areas. Since all ma-chinery vibrates and moves to a certainextent, clamps and ties can fatigue withage. Inspect fasteners frequently andtighten or replace them as necessary.


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56 Fuel System

Fuel FiltersNOTE! When draining the primary fuelfilter, collect the waste in a fuelproof con-tainer. Always dispose of coolant accordingto Federal or local regulations. Take thedrained fuel and water to a recycle or wastemanagement center.

For fuel filter change intervals see FuelFilter Change Intervals page 124.

For other engines, the engine manufacturersrecommend changing the fuel filter at everyoil change. For bleeding the fuel system,see page 130 for D12 and page 132 for D7engines or the engine manufacturers opera-tors manual for other engines. W2001067

Fuel Sulfur ContentFuel sold after 1994 for highway use canonly contain a maximum sulfur content of0.05% by weight. This was done to reduceparticle emissions in the exhaust.

The sulfur content for off-highway use con-tinues to be specified at a maximum of0.5% by weight. The use of a fuel contain-ing 0.5% or higher level of sulfur,necessitates more frequent engine oilchanges because of sulfur deposits andhigher corrosion risk. If using fuels withhigh sulfur content, the oil change intervalsmust be cut in half. See Sulfur Level and

TBN page 72 for more information.

NOTE! The use of low sulfur diesel oilfuel does not permit extension of engine oilchange intervals or oil filter changes.


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Fuel System 57

Cetane NumberDirect injected diesel engines require aminimum cetane number of 40 under nor-mal starting conditions. Fuel with a highercetane value may be required for high alti-tude or cold weather operation.

FiltrationFuel should be clean and free of contami-nation. Clean fuels should have no morethan 0.1% of sediment and water.

If fuel is stored on site, make sure that:

Keep storage tank covered to preventwater entry.

Do not use a tank made of galvanizedmetal or any galvanized piping fordiesel oil storage. Diesel will reactwith the zinc, forming solids that canclog fuel filters and cause engine dam-age.

Fuel stored for a long time may oxi-dize and form solids, causing filteringproblems.

Keep the area around the fill capclean. Tilt the tank slightly toward thedrainplug area so water and sedimentcan be easily drained.

Generally, fuel contamination occurs as theresult of improper fuel handling. The mostcommon types of contamination are water,dirt and microbial growth (black slime).The formation of varnishes and gums result-ing from poor fuel stability or long storage(stale fuel) also affects fuel quality. Thebest treatment for contamination is preven-tion by maintaining a clean storage systemand choosing a reputable fuel supplier.


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58 Fuel System

Fuel Pour PointFuel pour point should be at least 10 F(6 C) lower than the lowest ambient tem-perature at which the engine must start andoperate. Lower pour points of diesel fuelgrade No. 1D may be necessary in ex-tremely cold weather.

Fuel Cloud PointThe cloud point should be below the lowestambient temperature at which the enginemust start and operate, to prevent the fuelfilter elements from plugging with waxcrystals.

Fuel ViscosityFuel viscosity must be kept above 1.4 cStat 100 F (38 C) to provide adequate fuelsystem lubrication. The viscosity also hasan effect on the atomization of the fuelwhen it is injected into the cylinders.


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Fuel System 59

Fuel Additives

GeneralFuel additives are generally not recom-mended or needed for fuels listed earlier.Cetane improvers can be used as necessary.Biocides may be needed to eliminate mi-croorganism growth in storage tanks. Incold conditions, treatment for water in thevehicle tanks may also be necessary.

Consult your fuel supplier about the use ofadditives to prevent incompatibility amongadditives already in the fuel and the addi-tives to be used.

Supplemental Fuel Enhancers

CAUTION

Supplemental additives are not recom-mended because of a high risk ofinjection system problems or enginedamage.

There are many aftermarket products avail-able today which are intended to be addedby the customer. They generally increaseoperating cost without providing benefits.Included are a variety of independentlymarketed products which claim to be:

Cetane improvers

Emission control additives

Detergents

Combustion improvers

Smoke suppressants

Cold weather flow improvers


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60 Fuel System

NOTE! Repair expenses resulting frommalfunctions in the fuel system or with en-gine components when fuel enhancers havebeen used are not covered under warranty.

Some fuel additives can be used to providetemporary relief but they do not replacegood fuel handling practices. These prod-ucts can be used:

Isopropyl Alcohol Use 1 pint per125 gallons (1/2 liter per 500 liters) offuel for winter freeze-up protection.

Biocide For treatment of microbegrowth or black slime. Follow man-

ufacturers instruction for treatment.


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Fuel System 61

Prohibited Additives

The following additives are specificallyNOT allowed and must NOT be mixed in

with the vehicle diesel fuel:

Used Lubricating Oil:Volvo Trucks North America, Inc. doesnot recommend the use of any type ofused lubricating oil as an extender inthe diesel fuel. Used lubrication oilcontains solids and acids from the

combustion process that can severely

corrode parts of the injection sys-

tem, resulting in reduced power and

higher maintenance cost over time.

Gasoline:

Adding gasoline to diesel fuel will re-duce the cetane number and increasecombustion temperature. If a tank con-tains a diesel fuel/gasoline mixture, itshould be drained and cleaned as soonas possible.


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62 Fuel System

Alternative FuelsAlternative fuels can be of several differenttypes. There are vegetable based fuels, avia-tion fuel and recycled petroleum based fuels

that are used in combustion engines. Thesein general are not compatible with modernheavy duty over-the-road vehicle engines.

The use of unauthorized fuels may compro-mise the levels of pollutants in the exhaustto the point where the engine does not meetthe emission requirements. This wouldmake the vehicle illegal to drive on publicroads.

DO NOT use any kind of alternative fuelunless specifically authorized by VolvoTrucks North America, Inc.


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Oil System 63

Engine Oil

GeneralKeep the engine oil at the proper level and

change it at the recommended intervals. Al-ways replace the oil filters at the same timeas when the oil is changed.

Always follow the oil change intervals anduse the oil types that are recommended bythe engine manufacturers. Oil change inter-vals for Volvo engines are found on page65. Viscosity and capacity tables can befound beginning on page 161. Other enginemanufacturers have different policiesregarding their products and should be con-sulted if a different change interval isdesired. Contact your Volvo Truck dealerfor more information.

For information on synthetic oil, see page70.

W1000077

NOTE! Always dispose of oil according toFederal or local regulations. Used oildisposed of in nature or waterways contam-inates our drinking water and kills wildlife.Take all used oil to a recycling or wastecollection center.


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64 Oil System

Oil QualityVolvo Trucks North America, Inc. recog-nizes and recommends engine oils thatmeet or exceed the standards given byAmerican Petroleum Institute (API) for theoil classifications listed in this manual.Only oils licensed to carry the API symbolshould be used. Lubricants meeting APIstandards have provided maximum enginelife when used together with the recom-mended oil and oil filter change intervals.

Engines meeting the 2000 emissions re-

quirements operate under higher soot

loading conditions than previous engines.

This has led Volvo to require a highergrade oil that meets both API CH-4 and

VDS-2 quality standards for model year

2000 Volvo engines. This type oil is re-

quired for normal oil intervals.

Normal grade engine oils for all engines

in vehicles produced by Volvo Trucks

North America, Inc. must meet or exceed

the API classifications CG-4 or CH-4.

Also, Volvo has a specification called

Volvo Drain Specification (VDS) forVolvo engines. These types of oil necessi-

tate more frequent oil changes (shorter

intervals).

See page 65 for interval recommendationsfor Volvo engines. See other enginemanufacturers Operators Manuals for in-formation on when and how to change theoil for those engines.

Oils that meet both API CH-4 and VDS-2are required for model year 2000 Volvo en-gines with normal oil drain intervals. Mostmajor oil companies have oils that meetthese specifications. A list of approved oilscan be found in Service Bulletin 175001.

W1000147

Typical API Symbol

CAUTION

Extra oil additives must not under anycircumstances be added to any engineoil used. Additives such as break-in oils,

top oils, graphites and friction reducingliquids are not necessary and may evenharm the engine.


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Oil System 65

Oil Change IntervalsThe length of time an engine is operatedbefore an oil change depends on the qualityof oil used, the type of fuel used, engine oilconsumption, vehicle application, level ofdust in the air, etc. The change intervalsgiven in this manual are maximum inter-vals. If the vehicle is operating inheavy-duty operation, dusty or off-roadconditions, using high sulfur fuels, etc., ad-

just the intervals down for more frequentoil changes.

NOTE! Oil filters should always bechanged when changing oil.

Oil FiltersAlways change oil filters when changingthe oil. There may be two or three filters onthe engine, one of which is a bypass filter.This should be changed at the same time as

the regular full-flow filter(s).

CAUTION

Use only the engine manufacturers oilfilter for replacement. Use of an oil filterthat does not meet specification couldresult in severe damage to bearings,crankshaft, etc. as a result of unfilteredoil entering the lubrication system.

W2003173

D12 oil filters


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66 Oil System

Oil Change Intervals, Volvo D7 EngineFirst oil change should be done at max.

10,000 km (6,000 miles).

There are different oil change intervals for

the D7 engine, depending on which oilquality is used. Always use the correct oilquality for your application and distancedriven.

For example, in longhaul transport (>7mpg;


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Oil System 67

Type ofOperation

Average fuelconsumption isunder 6.0 milesper gallon (over

4.0 liters per 10km)

Gross combinedweight (GCW)is greater than60,000 lb(27,000 kg)

Idle time is 40%or higher

Vehicle operatesoff road or industy areas

Vehicle operatesin inner city de-livery

Average fuel con-sumption is over6.0 miles per gal-lon (under 4.0

liters per 10 km) Gross combined

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vnl volvo operators manual maintenance and engine

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