Pre-Delivery Inspection
Contents
1. Measure from top of spring plates to top of cab suspen sion crossmember Correct ride height is 6 850 0 157 in 174 4 mm Group 17 Service Procedures W8000897 W7000046 Gasket for aluminum hubs W4002087 O ring for steel hubs Pre Delivery Inspection 8 Hood Latch and Tilt Check the hood latches for proper adjustment and oper ation Check operation of hood restraint cylinders Inspect splash shields Raise and lower the hood to ensure proper operation and make sure that the latches secure the hood when closed 9 Drive Axle Shaft Gaskets On vehicles where the axle shafts were removed for transportation check for cracks or tears in the gaskets or O rings If any damage can be seen replace gasket or O ring Remove transport cover Install new gasket for aluminum hub or O ring for steel hub Inspect gasket or O ring surface on the axle shaft to make sure it is clean Install axle shaft Fastener Torque Values ft lb Nm Thread Lock Nut Size in 0 75 16 275 25 372 34 1 0 Drive Axle Shaft Nuts On vehicles where the axle shafts were removed for transportation check tighten the drive axle shaft nuts to the correct torque as indicated Group 17 Service Procedures W7000774 W7000437 Pre Delivery Inspection 1 1 Fuel Tanks Remove protective coating on polished tanks if tank is exp2. e Incomplete Vehicle Document e Wheel Alignment Information VAN DANGER a e Truck Order Bill Listing e Weight Certificate Before working on a vehicle set the parking brakes place the transmission in neutral and block the e Tire Warranty wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Note Other literature may be provided depending on the configuration of the truck Such literature includes but is not limited to e Engine Brakes e Radio etc Group 17 Service Procedures W8000893 W8000895 Pre Delivery Inspection 2 Horn s Sound the air horn 1 and electric horn 2 to ensure proper operation Each horn should have a strong clear tone 3 Safety Belts Sleeper Restraints Check the safety belts for function and condition Oper ate the belt latch and verify that it locks and unlocks properly Check belts for e Smooth rolling when rolling out and retracting e Check mounting bolt tightness and for any defects in hardware If the vehicle is a sleeper model verify that the restraint harness latches operate properly Check condition of the webbing Group 17 Service Procedures W8002768 W3000756 W3000809 Pre Delivery Inspection 4 Seats Check both seats for proper function Operate the switches to verify function If seat has the heater option turn on t
3. NLGI No 2 Use liberally in the slack adjuster Make sure the grease purges through the seal on the brake cam Note If the brake cam seal does not purge make sure the inner seal does not purge into the brake drum and onto the brake linings Note Low maintenance brake options such as Mer itor LX500 brakes are frequently specified If vehicle is so equipped follow manufacturer s procedures lubrication type and service intervals carefully 10 11 12 13 14 15 16 17 18 Pre Delivery Inspection Use a lithium based grease with specification API NLGI No 2 Only use a hand operated grease gun The high pressure from an air operated grease gun will damage the seal Use a lithium based grease with specification API NLGI No 2 Note Always grease a Volvo front axle with the wheels on the ground Note To grease non Volvo axles they are typically greased with the wheels on the ground Consult with the axle manufacturer for the latest recommendation Use a lithium based grease with specification API NLGI No 2 Note Volvo axles may use a greased for life tierod No provisions for adding grease are available Use a lithium based grease with EP additives to specification API NLGI No 2 Note Make absolutely sure that grease purges out of all four seals of the U joint Use a lithium based grease with EP additives to specification API NLGI No 2 Make sure the grease purges out of both the outer an
4. information This is not a step by step procedures manual and when necessary other manuals will be noted when reference is needed Where the phrase Check for proper operation is used it is assumed that an experienced technician with a working knowledge of the vehicle and its basic operation is performing the check Technicians not familiar with basic vehicle operation should receive adequate training to the point where an inspec tion of the vehicle can be carried out with an assurance that the judgement to pass an item as being in good condition is made with certainty When using the Pre Delivery Inspection Form page 22 note on the back of the form under NOTES any defects found when doing the inspection Group 17 Service Procedures Pre Delivery Inspection Pre Delivery Inspection 1711 09 02 01 Pre Delivery Inspection The Pre Delivery Inspection Form page 22 should be used when doing the Pre Delivery Inspection Fill in the form and add a copy to the owner s package Cab Interior 1 Vehicle Literature Check the vinyl envelope that is provided with the vehi cle to see that it contains the following information e Operator s Manual for Vehicle CUSTOMER MAINFENANCE AND IN e Operator s Manual Maintenance and Engine RMATIONZ __ e Operators Manual Vendor Engines or Transmis sions e Dealer Directory e Truck Warranty Certificate e Product Report e Publications Order Form
5. Front Axle Check for proper installation to specific torque 21 Front Axle Hubs Check oil level Check for visible leaks 22 Steering System Check oil level Check for visible leaks 23 Cab Tilt Pump WX WXLL Check oil level Check for visible leaks 24 Cooling System Check coolant level Check for leaks Freeze protection F ee 25 Clutch Reservoir Check fluid level Check for visible leaks 26 Lubrication Lubricate chassis per the lube chart 23 Group 17 Service Procedures Pre Delivery Inspection Test Drive 27 Before Test Drive Check controls gauges and indicator lights on dash for proper function Check air pressure build up Check holding ability of service and parking brakes Check windshield wipers and washers for proper operation 28 During Test Drive Check engine for proper performance and operation Check steering wheel and handling capabilities Check clutch and transmission for proper performance and operation Check heater air conditioner for proper operation Check service and parking brakes for proper operation Check engine retarder exhaust brake for proper operation Check inter axle differential locks for proper operation Check inter wheel differential locks for proper operation 29 After Test Drive Check graphic display for any diagnostic message
6. Service Manual Trucks Group 171 500 Pre Delivery Inspection VN VHD PV776 TSP147914 VOLVO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to April 2001 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 believed to have a significant bearing on this manual supplementary ser vice 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 refer ence to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for gen eral information and no reference is made to an S R 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 oc cur Volvo Trucks North America Inc Greensboro NC
7. USA Order number PV776 TSP147914 Repl This manual replaces Service Manual 171 500 Pre Delivery Inspection publication no PV776 TSP142924 and Supplement 171 500 01 Axle Shaft Gaskets Pre Delivery publication no PV776 TSP144734 of 8 2000 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 me chanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc Contents General acri 3 Pre Delivery NSPE aspas ias 3 Pre Delivery Inspection 5 1711 09 02 01 Pre Delivery Inspection ii 5 ADINE calesse ica 5 Cab Exterior Including the CHASS IS iii 8 Fluid Levels and LUDAGAHONI rca 12 TRUDI sean 19 Pre Delivery Inspection FO c ca 22 Feedback Group 17 General Pre Delivery Inspection 7 D UFOTO Ho Sl R a 4 E 4 4 Nu LE O FF W1000076 The Pre Delivery Service Manual is written for the purpose of assuring the customer and Volvo Trucks North America Inc that the vehicle is checked and inspected before actual delivery to the customer This manual together with the Operator s Manual for the vehicle are a help to service personnel and should be used with the Pre Delivery Inspection Sheet at the end of this
8. a Ltd 6490 Vipond Drive Mississauga Ontario L5T 1W8 http Awww volvotrucks volvo com PV776 TSP147914 1000 04 2001 Volvo Trucks North America Inc 2001
9. and or wheels Failure to do so can result in unexpected fluids A hot engine and or fluids can cause burns or vehicle movement and can cause serious personal in can permanently damage test equipment jury or death Note Check fluid levels with the vehicle on level ground If the fluid level is low add as necessary If oil has to be added use only the same type of oil that is already in the component Also check for any leaks and note on the back of the Pre Delivery Inspection Form page 22 1 6 Engine Do not mix synthetic oils with petroleum based oils Mixing synthetic oils with petroleum based oils can cause component failure and or component damage Check the engine oil level The acceptable level is be tween the MIN and MAX marks on the dipstick If the oil level is above the top mark oil should be removed from the oil sump Check for visible oil leaks W2002047 Improper Oil 1 7 Transmission Oil Cooler Do not mix synthetic oils with petroleum based oils Mixing synthetic oils with petroleum based oils can cause component failure and or component damage Check the oil level in the transmission by removing the fill level plug in the side of the transmission housing or check with the dipstick The oil should be level with the bottom of the fill level plug hole or according to the mark waaoo7 e ing on the dipstick Check for visible oil leaks For Allison automatic
10. arder exhaust brake for proper op eration Make sure the brake function disengages by e Depressing either the accelerator or clutch pedal e Engine speed falling below 1200 rpm 1200 r min e Vehicle speed falling below 2 mph 3 km h e Engaging PTO Group 17 Service Procedures Pre Delivery Inspection Check the inter axle differential lock for proper operation If equipped check the inter wheel differential lock for proper operation W3000810 29 After Test Drive Diagnostic Messages Check the Graphic Display for any diagnostic messages W3000924 n Check the exhaust system for leaks Check the vehicle for any fluid oil water or air leaks Check the A C diagnostic module If the green light is slowly blinking the A C unit is OK If the vehicle is equipped with a sleeper cab check the function of the A C and heater unit in the sleeper com partment mar W8000995 21 Group 17 Service Procedures Pre Delivery Inspection Form Use the following Pre Delivery Inspection form to check off the points as they are completed and to note test val ues 22 Pre Delivery Inspection Group 17 Service Procedures Pre Delivery Inspection Customer Truck Model Pre Delivery Inspection VOLVO Engine Model amp S N VIN Transm Model amp S N Mileage Rear Axle Model amp S N Repair Order Date Points of Service Indicate S
11. d inner seals If nec essary adjust the lubrication schedule to include greasing the bogie bearing as often as daily in applications where the bogie runs in corrosive con ditions or is submerged in water Use a lithium based grease with EP additives to specification API NLGI No 2 Do not over grease the throwout bearing as grease may get into the clutch See the manufacturer s operator s manual for inter vals and quantity If equipped with auxiliary lift axles grease and lubri cate according to notes 3 9 11 and 12 Use a lithium based grease with EP additives to specification API NLGI No 2 to grease both ball joints Group 17 Service Procedures Pre Delivery Inspection Test Drive 27 Before Test Drive Note Make sure to note any observations made before during and after the test drive on the Pre Delivery In spection Form page 22 Before the test drive check the following for proper oper ation refer to the Operator s Manual e Dash controls gauges and indicator lights e Air pressure build up e Holding ability of service and parking brakes e Windshield wipers and washers Start the engine and check for rapid build up of air pres sure Depress the brakes and deplete air in the tanks to check air pressure recovery The ability to disengage the parking brake should happen after 30 seconds of run ning at 1000 rpm from when air tanks were empty 28 During Test Drive Dur
12. ervice Rating OK v Adjusted X Repaired R Cab Interior 1 Vehicle Literature Check for correct manuals Interior Lights 2 Horn s Check operation of electric and or air horns 3 Safety Belts Sleeper Restraints Check mounting condition and operation 4 Seats Check mounting condition and operation 5 Radio Check for proper operation 6 Check for proper operation Cab Exterior Including Chassis 7 Cab Check mounting and condition 8 Hood Latch and Tilt VN VHD Check latches adjustment and operation 9 Drive Axle Shaft Gaskets Check for cracks or tears 10 Drive Axle Shaft Nuts Torque nuts only if shafts were removed for transport 11 Fuel Tanks Remove protective coating on polished fuel tank if exposed 12 Wheel Nuts Tighten inner and outer wheel nuts to proper torque 13 Tires Check tire pressure 14 Exterior Lights Check headlights marker lights turn signals stop and tail lights for proper operation 15 Exhaust Clamp Check for proper intsallation to specific torque Fluid Levels and Lubrication 16 Engine Check oil level Check for visible leaks 17 Transmission Oil Cooler Check oil level Check for visible leaks 18 Rear Axle s Check oil level Check for visible leaks 19 Auxiliary Transfer Case Check oil level Check for visible leaks 20
13. he switch and feel for heat Note The heater will only work at ambient temperatures under 103 5 F 40 3 C 5 Radio Turn on the radio if equipped and verify that it operates without distortion or static noise Check all functions of e Radio e Tape deck e CD player Note Use the same cassette and or CD recording every time to test the sound system 6 Interior Lights Operate the switches of all interior lights to verify func tion and that the bulbs light up e Ceiling light e Bunk lights e Door lights e Luggage compartment lights Note The overhead light is operated by the door switch in one position and will stay on in the other position Group 17 Service Procedures Cab Exterior Including the Chassis W1000061 W8001288 W8000855 Pre Delivery Inspection 7 Cab AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Check all paint on the cab hood and chassis Note any discrepancies Check all chrome for example grille chrome acces sories etc for damage or discoloration Check cab mounting and suspension Check the ride height for cab air suspension For the proper operation for checking the cab suspension refer to service infor mation in group 81
14. ing the test drive check the following for proper per formance and listen for any unusual noise or vibration Check engine controls and performance while moving through the gears The accelerator should move smoothly and without any hesitation in engine response The engine should accelerate smoothly and without hes itation misses or surges W1000065 Check the steering wheel and handling capabilities of the vehicle The steering should operate precisely and without shimmies tracking or vibrations When operated at low speed and in close quarters doing full turns the steering should operate without binding in any spot W1000064 Group 17 Service Procedures 20 W2001084 Pre Delivery Inspection Check the clutch for proper operation The clutch should have smooth operation and engagement when shifting gears Check the transmission for ease of shifting and proper operation The lever should move smoothly through the gear pattern Listen for unusual noises during shifting Check the heater and A C for proper operation Operate all controls and run the fan on all speeds Check the service and parking brakes for proper opera tion AN DANGER When operating a tractor bobtail without a trailer or on slippery roads the engine brake switch must be in the OFF position Failure to follow these instructions can result in loss of vehicle control and serious personal injury or death Check the engine ret
15. not mix synthetic oils with petroleum based oils Mixing synthetic oils with petroleum based oils can cause component failure and or component damage WA000749 Check fluid level in the clutch fluid reservoir Add if nec essary 26 Lubrication Grease all points as indicated in the Lubrication Chart page 17 Note When necessary refer to the Preventive Mainte nance Service Manual for more information and procedures Group 17 Service Procedures Lubrication Chart Spring hanger 2 Note 8 Slack adjuster amp brake cam 4 Note 9 Steering gear 1 Note 10 Kingpin upper amp lower 4 Note 11 Tierod 2 Note 12 Spring hanger 4 Note 8 Clutch bearing and linkage Note 15 U Joint 1 Note 13 U Joint 1 Note 13 U Joint 1 Note 13 Slack adjuster amp brake Cam 4 Note 9 T Ride bogie beam 2 Note 14 Slack adjuster amp brake Cam 4 Note 9 There are notes for each type of lubrication on the next page Read the notes before selecting a lubricant A O lt Grease Hub Oil Engine Oil Hydraulic Oil Steering Fluid y Se e e A SUNDAY Pre Delivery Inspection Coolant level Note 1 Steering assist cylinder Note 18 Power steering fluid Note 2 Wheel bearings Note 3 Engine oil amp filter Note 4 Clutch cylinder fluid Note 5 Automatic transmission Note 16 Man
16. osed 1 2 Wheel Nuts All disc wheels for the VN or VHD series have fasteners that require a torque of 450 ft lb 610 Nm For dual wheels the following procedure must be used 1 Loosen outer nuts 2 Tighten inner nuts to a torque of 450 ft lb 610 Nm 3 Tighten outer nuts to a torque of 450 ft lb 610 Nm For spoke wheels check the manufacturer specifications 1 3 Tires Check the tires for proper inflation and leak test the valve stems Group 17 Service Procedures W2003594 Inserting stack pipe to stops 1 Stops 2 31 2in 38 1 mm W2003595 Aligning clamp 1 Correct 2 Incorrect Pre Delivery Inspection 1 4 Exterior Lights Check headlights marker lights turn signals stop and tail lights for proper operation Check headlight aim 1 5 Exhaust Clamp If the exhaust stack has been removed during towing the clamp must be retorqued after reinstallation of the stack pipe Check to be sure the top edge of the clamp is flush with the top of the muffler The clamp must cover the slots Finish tightening nut to a torque of 32 37 ft lb 43 5 50 Nm Group 17 Service Procedures Pre Delivery Inspection Fluid Levels and Lubrication A pace Before working on a vehicle set the parking brakes HOT ENGINE Keep yourself and your test equipment place the transmission in neutral and block the clear of all moving parts or hot engine parts
17. s Check exhaust system for leaks Check vehicle for other fluid and or air leaks Check A C diagnostic module Check function of A C and heater unit in sleeper if equipped This vehicle has been properly inspected and any correction or repairs have been done This vehicle is roadworthy and ready to be delivered to the purchaser This form replaces all previous forms F7760 010 F7760 011 F7760 023 F7760 023A and FV7760 023 Dealer Signature Date Notes 24 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 of Volvo trucks 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 Volvo Trucks North America INC Dept 516 Service Publications a eeeeteetetteteteeteaeeteeeteaeeeeeeeeaeeteaeeseaeeeeeseneeeneeeenes 7825 National Service Road 0 ii i P 0 B0X26115 Aiace iaia dai fe Greensboro NC 27402 6115 0 ii USA Fax 336 393 3170 Comments proposals VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canad
18. th petroleum based oils Mixing synthetic oils with petroleum based oils can cause component failure and or component damage Check the fluid level in the power steering reservoir with the engine off The level should be at the full mark on the dipstick Check for visible leaks Note Do not overfill the power steering reservoir or fill with the engine running For proper fluid type refer to decal affixed to the power steering reservoir On vehicles equipped with steering helper cylinder or gear on the right side of the frame check the compo nents for visible leaks 23 Cab Tilt Pump Not used for the VN or VHD series Group 17 Service Procedures Pre Delivery Inspection Cooling System 24 Do not remove the coolant fill cap or cap on the ex pansion tank until coolant temperature is less than 120 F 50 C Otherwise scalding steam or fluid may escape under pressure which can cause serious in jury Do not work near the fan with the engine running or the ignition in the ON position The engine fan can en gage at any time without warning Anyone near the fan when it turns on could be seriously injured Check to see that the coolant anti freeze in the radiator is at the proper level Pressure test the system and check for leaks For information refer to service informa tion in group 26 Group 17 Service Procedures Pre Delivery Inspection 25 Clutch Reservoir Do
19. transmission refer to the Allison Operator s Manual for proper fluid level checking proce dures Group 17 Service Procedures Pre Delivery Inspection 1 8 Rear Axle s Most rear differentials have a large screw and nut pro truding from the housing The screw and nut hold the CORRECT thrust plate shoe against the ring gear and are not to be confused with the fill level plug n Do not mix synthetic oils with petroleum based oils Mixing synthetic oils with petroleum based oils can cause component failure and or component damage INCORRECT Check the oil in the differential by removing the fill level W0000233 plug in the housing The oil should be level with the bot tom of the fill level plug hole Check for visible oil leaks 1 9 Auxiliary Transfer Case Not offered for the VN or VHD series 20 Front Axle Tighten the spring U bolt nuts to a torque of 310 ft lb 420 Nm W6000877 Group 17 Service Procedures W7000438 W6001428 Pre Delivery Inspection 21 Front Axle Hubs Do not mix synthetic oils with petroleum based oils Mixing synthetic oils with petroleum based oils can cause component failure and or component damage For front axles equipped with oil lubricated wheel bear ings check the fluid level in front axle hubs Check for visible leaks 2 2 Steering System Do not mix synthetic oils wi
20. ual transmission Note 6 Auxiliary axle s Note 17 Rear axle Note 7 Rear axle Note 7 W1000146 Coolant Aut Transm Fluid Man Transm Oil Rear Axle Oil Brake Fluid 17 Group 17 Service Procedures Lubrication Chart Notes Do not mix synthetic oils with petroleum based oils Mixing synthetic oils with petroleum based oils can cause component failure and or component damage 1 Add if necessary Only use pre mixed clean water and antifreeze in a 50 50 mix Add only the same type antifreeze that is extended life or standard 2 Check the fluid in the reservoir with the dipstick Add if necessary 3 Change the oil or grease only in connection with work on the hub or if dirt is found in the lubrication 4 Change the oil according to the schedule in TSI Service Bulletin 175 001 5 Check that the fluid is at the correct level If needed add fluid 6 Level should be to the bottom of the inspection hole See TSI 175 001 for correct oil 7 Check the oil level in the rear axles The oil should be level with the inspection hole Add if necessary See TSI 175 001 for correct oil 8 Use a lithium based grease with specification API NLGI No 2 When lubricating the springs lift the axle off of the floor suspend the frame with axle stands and lower the axle The spring bushings are now in the position where grease can be added to the contact surfaces 9 Use a lithium based grease with specification API
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