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Operator`s Manual VNL and VNM - Heavy Haulers RV Resource

1. W8001837 Additional Safety Features 61 SRS Airbag The SRS airbag is intended to supple ment not replace the standard safety belt The airbag is not deployed when the truck is hit from behind from the side or if it rolls over For best pro tection sit in a normal upright position Always wear the safety belt For added safety the vehicle may be equipped with an airbag or SRS Supple mental Restraint System as a supplement to the standard three point anchored safety belt The SRS is designed to reduce the risk of injury to the driver s face and upper part of the body Together with the safety belt the airbag helps prevent the driver from be ing thrown against the steering wheel windshield or other hard surfaces in the cab The Volvo SRS Airbag provides increased protection in frontal collisions where the vehicle collides with a fixed or heavy object with enough force to activate the sensors which then activates the airbag Damage to the vehicle is not always proportional to whether the SRS Airbag deploys or not The SRS Airbag is not designed to be acti vated with e Collision from the sides e Collision from the rear e Rolling over e Head on collisions at low speed or against soft objects such as bushes snow drifts etc 62 Additional Safety Features SRS System The inflatable airbag is folded into the cen ter of the steering wheel It inflates in th
2. W8002168 221 222 Cab Interior and Sleeper To fill the fresh water tank unscrew the fill hose from the elbow fitting and remove the fill cap 5 from the tank The fill hose should be connected to a hose with a gardenhose type fitting Before turning the water on turn the valve handle 6 on the fill hose to the side to close the valve see lower illustration When the end of the fill hose is inserted in the water reservoir open the valve slowly to fill The valve is fully open when the handle is parallel with the hose W8002167 When the tank is filled reinstall the fill hose on the elbow fitting Do not tighten more than finger tight Make sure that the valve handle now is fully open 1 to allow venting If the valve is left in any of the closed positions 2 the pumped out water may generate an under pressure in the tank interfering with the pump operation NOTE The valve positions are shown as viewed from inside the cab W8002169 Cab Interior and Sleeper 223 Waste Water Tank When the water is drained from the sink it is collected in a waste water tank behind the fresh water tank Waste water tank vol ume is 5 gallons 19 liters The tank is fastened to the floor with a strap that can be easily opened for tank removal Before removing the waste water tank loosen the strap around the tank and un screw the drain hose from the inlet cap Carry the tank to an approved dump st
3. 112 Switches Pneumatic 110 Switches Right Cluster 106 T Table In VN 770 217 Tachometer 82 TCS Switch 2 5 aaa 106 TCS Telltale qo He es SS 93 346 Index Telephone a aoaaa 234 Television aaa 235 Telltale Bulb Replacing 95 Telltale Overview 72 Telltale Sth Wheel Lock 86 Telltale ABS 0 2 88 Telltale Air Suspension 88 Telltale Auto Neutral 94 Telltale Check Transmission 92 Telltale Diff Lock 86 Telltale Hi Beam 87 Telltale INFO ui ae ee 79 Telltale Master Warning 84 Telltale Mirror Defrost 88 Telltale No Charge 81 Telltale Parking Brake 87 Telltale Preheater 78 Telltale Safety Belt 87 Telltale Stop Engine 80 Telltale TCS 2 eu he 93 Telltale Transmission Temperature 92 Temperature Gauge Coolant 75 Tire Inflation wae a aw 314 Towing Information General 335 Towing Procedures 337 Traction Control System TCS 287 Trailer Brake Hand Control 283 Trailer Coupling Procedures 323 Trailer Supply Valve 278 Trailer Uncoupling 328 Turbo Boost Pressure Gauge 77 Turn Signal aa aaa 97 TV Antenna aaa 231 U Uphill Operation 263 V Vehicle Access oaoa a 20 Vendor Component Information 1 Ventilation ac len Bisa Gd Ga 185 Voltmeter 2 2 4 ave ayes aes 125 Volvo Act
4. The buckle portion of the safety belt sys tem is different depending on the seat option chosen The National standard and comfort seat has a separate buckle that is attached to a floor anchor by a seat strap This seat strap is not adjustable and does not need to be adjusted W8001836 The buckle for the seat is bolted to the seat floor If a comfort clip is used on the safety belt always adjust the latch so that there is a maximum of 1 in 25 mm slack between the belt and chest about the width of two fingers If a larger slack is allowed the ef fectiveness of the safety belt is decreased in the event of a collision Operation of the clip is described on page 60 19 Make sure the safety belt is completely re tracted and out of the way when not in use ee W8001837 Additional Safety Features Sleeper Safety Restraint N DANGER Always use the safety restraint when the vehicle is in motion Failure to do so not only may cause severe injuries or death to the passenger in the event of an acci dent but also poses a danger of injuries to other occupants of the vehicle N DANGER Anytime the vehicle is in motion a pas senger using the sleeper bunk should be strapped in using the safety restraint The top bunk should always be used with the harness in place whether the vehicle is in motion or not Falling from the upper bunk can result i
5. 68 82 Right Instrument Section 000 89 Changing Telltale Bulbs In Cluster 95 Steering Column Switches 97 Left Switch Cluster sesceresierierira 99 Driving Light Switches cissewnies 104 Right Switch Cluster 0 00000 106 Pneumatic Switch Cluster 110 Optional Switch Cluster 112 Miscellaneous Switches 113 Graphic Display eee 114 Graphic Display Overview 114 Graphic Display Controls 115 Graphic Display Telltales 0 0 0 0 117 Information and Stop Messages 118 Intormaton Telltale scacisveravaacecavesrsoetes 119 Stop elhalt seredes 126 Acknowledge Information and Stop DORM OS nia 130 Main Menu Set Up Mode 132 Main Menu System Diagnostic 137 Main Menu Data Log Mode Volvo Engine Only osmsssimansonsans 152 Main Menu Password Input 158 Maim Menmu Gaug csunrensnarssai 159 Main Menu Fuel Economy option 163 Main Menu Time Distance 165 Main Menu FAULTS 0006 170 Heating and Air Conditioning 174 E EE E E S T 174 Climate Unit Main Control Panel 175 Sleeper Climate Unit sesnresiorisens 183 Cab VOMA OR ciecseviroriavesevesicrmrvcrerstel 185 CADAN FIIS gencrieroniasanna 187 Parking Heater optional 0 188 A C Diagnostic Module 0 194 Noe E E A A 195 ONE faerie 195
6. 187 W8002474 W8002473 188 Heating and Air Conditioning Parking Heater optional DANGER Do not fuel the vehicle or handle flammable liquids in the vicinity of an operating parking heater The fuel vapors can be ignited causing an explo sion or fire resulting in severe personal injury or death DANGER Do not store flammable items close to the parking heater or put items on top of it Flammable items should not be closer than 2 inches 50 mm The item may ignite and cause a fire resulting in severe personal injury or death DANGER Do not run heater while vehicle is in an enclosed area The exhaust gasses con tain carbon monoxide CO If not vented to the atmosphere there could be a buildup of dangerous levels of CO which may lead to unconsciousness and later death The parking heater is a diesel fuel burner that heats the air in the cab Air is taken from the cab and returned heated up Com bustion air and exhaust is taken from and released to the outside air To safeguard from the heater operating af ter a turnover accident there is a fuel shut off valve in the fuel delivery system The parking heater is a very hot object Do not touch the heater when it is in op eration or shortly thereafter Touching a heater may cause burns to exposed skin CAUTION The heater air cab inlet is located in the bunk wall in front of the heater Do not attempt to put small items o
7. amp the same wheel sensors as the ABS to de termine if one set of drive wheels is spinning much more rapidly than the wheel g TCS set on the other side If the TCS determines g that a wheel is spinning with vehicle speed T below 25 mph 40 km h it operates the W3000962 brake system to apply some brake force to stop the spinning wheel s This puts the drive power over to the stationary wheel s If vehicle speed is above 25 mph 40 km h a signal is sent to the engine ECU which reduces the engine speed to be consistent with vehicle speed This action helps reduce the amount of wheel spin and gives the operator greater vehicle control The TCS includes a switch to turn of the function When the switch is in the OFF position the TCS operates normally to in crease traction if the drive wheels are spinning When the switch is pressed once the TCS telltale in the instrument cluster blinks continuously indicating that the TCS is in mud snow mode W3001336 The mud snow mode increases available traction on soft surfaces like snow slush or mud by slightly increasing the allowable wheel spin This prevents the wheels from getting bogged down The TCS will resume normal operation when the TCS switch is pressed again and the TCS telltale goes out or when the ignition is turned off A N CAUTION Do not engage the differential locks while wheels are spinning Serious dam age to the differential will occur See
8. National Standard Seat Adjustments 196 National Comfort Seat Adjustments 197 Volvo Standard Seat Adjustments 198 Volvo Comfort Seat Adjustments 199 National Stationary Seat 0 202 Cab Interior and Sleeper 203 Interior Reading Lights 203 Storage Compartments eee 206 sleeper Bunks pocsscerosereuins 212 VN 660 and VN 770 Sleeper Table 217 Sleeper Compartment Sink 000 220 Miscellaneous Sleeper Equipment 224 Communication and Entertainment 231 PG prad 231 Stered Radi ccicioissiedciiounnsss 233 Communication Equipment 234 DORE sea caieeenesasies 235 Fuel Economy Driving 237 Fuel Ec nomy siictitomnicoionnn 237 Engine Start and Operation 244 Starting the Engine snsacensananaananves 244 Cold Weather Start and Operation 249 Engine Operation aniiccsnsunauiinann 256 Cruise CA cascatsarcraeaneassaiansenins 265 Fite Tonk Caps simunbisisnamion 267 Clutch and Transmission 269 TIEN E E E E 269 Folding Gear Lever option 270 PRP ua 272 51 O E EEE E tes E T ZIF Electrical System eee eens 292 Electrical SyStGUW lt scciscsvscessiaveiaecaviiess 292 Power Steering cicsccesecsescccscicosescasseisrces 309 Ceneral sccvsectnidierbinnacantncssees 309 Axles and Wheels 00 000 311 PISS sigacansanatriarnanaiadmacsensinans 311 Wedle asnan aa 31
9. Fuel Heater Filter option If running in very cold weather a heated fuel filter should be added A number of different fuel heaters are available as op tions They are electrically heated and regulated by a thermostat They are typi cally built into the primary fuel filter housing W2001067 Fuel Tank Heater option An in tank fuel heater is also available In tank heaters use hot engine coolant to warm the fuel This prevents wax formation in the fuel during cold season operation These heaters are thermostatically con trolled and will automatically raise the fuel temperature to an optimum level Engine Start and Operation 255 Winterfront Volvo Trucks North America Inc does not AN recommend the use of winterfronts shutters CAUTION or any other shield in front of the grille or radiator package under normal circum stances Failure to remove the winterfront when temperatures go above 15 F 25 C could cause severe damage to engine charge air cooler and or loss of fuel economy Today s electronically controlled engines are designed to operate in cold tempera tures without a winterfront These devices if not used properly can cause higher ex haust temperatures power loss excessive fan usage failure of the charge air cooler and a reduction in fuel economy Winterfronts are properly used in the win tertime during very cold weather with sustained temperatures below 15 F 25 C In thes
10. When disconnecting battery terminals al ways disconnect the main ground terminal first When reconnecting always connect the main ground terminal last Electrical System 295 W3002421 W3002368 296 Electrical System Battery Jump Starting and Charging To access the batteries on a vehicle equipped with side fairings open the fair ing access cover On the second battery from the front there are special longer posts installed to accept jumper cables When jumping batteries to start an engine it is important that the jumper cables are connected directly from one set of batteries in one vehicle to the other set of batteries in the other vehicle unless vehicle is W3000980 equipped with optional Emergency Start System This way the cranking current is carried through the proper starter wiring Connect the jumper cables to the positive or hot terminal first and ground terminal last When disconnecting the cables dis connect the ground terminal first Connect the jumper cable clamps to the discharged battery first and to the booster battery last Avoid creating sparks by making all con nections quickly and firmly Do not permit vehicles to touch each other when jump starting N DANGER Do not attempt to jump start a vehicle equipped with Delco Maintenance Free aes batteries if the test indicator is light yel low Replace the battery instead Jump starting may cause battery to ex plode
11. When the air conditioning button is pressed the fan speed control must be set on 1 through 4 for the air conditioning to start If the air conditioning button is pressed when the fan speed control is set on 0 the air conditioning will not start To set the air conditioning temperature ad just the temperature control and fan speed until the desired temperature air flow has been reached If the cab temperature needs adjusting the temperature or fan speed has to be adjusted again until the new desired temperature has been reached Heating and Air Conditioning 181 A C Automatic Control When the vehicle is equipped with Auto matic Temperature Control ATC the control panel has a button marked with aut for engaging the electronic control unit When ATC is engaged the green LED light in the button is on W8001471 The ATC air conditioning works with the coolant control valve as a thermostat making automatic adjustments with input from sensors for air output and for air in side of the cab However the fan speed may also have to be adjusted increasing or decreasing air flow to achieve correct cab temperature To use the ATC let the system run in the manual mode until the cab temperature has stabilized at a desirable temperature Then press the aut button to engage the auto matic control unit To set a new desired temperature simply slide the temperature control to a higher or lower setting and the system wil
12. 73008861 NOTE If the coolant temperature returns to normal shortly after exceeding the limit and no repair has been made the warning messages go out but there will be a fault message logged 76 Instruments and Controls C Engine Oil Pressure The gauge indicates oil pressure by a sensor directly connected to the engine lubrication system Normal oil pressure is 30 to 70 psi 210 to 480 kPa when the engine is at nor mal operating temperature At idle speed the pressure may drop to 5 to 20 psi 35 to 140 kPa When first starting a cold engine oil pressure may exceed 90 psi 620 kPa The LED light in the lower right corner of the gauge lights up solid when the oil pres sure is too low The pressure limit is dependent on the engine manufacturer elec tronic program When the gauge light comes on the red AASTOP telltale starts blinking the buzzer sounds and the oil pressure symbol appears on the graphic dis play The engine is at risk and the engine 4 controller may react by derating the engine 3003613 power for example Bring the vehicle to a safe stop where the problem can be checked With very low oil pressure the red STOP AN STOP telltale lights up solid The engine will shut down within 30 seconds from when the light came on Pull off the road as soon as possible without being a safety hazard W3003768 T3008861 DANGER Failure to take necessary action when the ASTOP telltale is o
13. Air tubing and electrical wiring se cured against snagging and chafing Left Fuel Tank s e Securely mounted and not damaged or leaking e Fuel lines secure and not leaking Check that shut off valves are open e Tank s full of fuel Cap on and secure Battery Area Open the battery box page 294 Bat tery box securely mounted to vehicle Batteries secured against movement page 294 e Battery cases not broken or leaking Battery cables free from damage e Tops of batteries and terminals clean and free from foreign material e If equipped replace battery lid and make sure it is securely fastened page 295 Pre Trip Inspection and Daily Maintenance 39 wee oon gt N Tassy In the Cab Check steps and grab handles for looseness or breakage page 23 Also clean them if there is any sub stance that makes them slippery which makes cab entry exit hazardous Start the engine If equipped check that exhaust rain cap opens when ac celerating engine Check gauges and telltale light func tion page 85 Check function of low air warning page 91 Check the Graphic Display for any fault codes page 114 Check clutch function page 269 If equipped check for clutch brake func tion Check windshield wipers and washers page 47 and horns including back up alarm if equipped Clean inside windshield door win dows and instruments Clean mirrors W0001230 Check climate contro
14. Failure to follow this guideline may re sult in a fall that can cause serious personal injury or death The steps on the vehicle are designed to conform with the requirements of 49 CFR 399 You should familiarize yourself with this Federal regulation Both the operator and passenger should exercise caution when entering or exiting the cab Use the steps and grab handles to safely get in and out of the cab to prevent injuries related to a slip and fall W8000928 General Entry Guidelines 1 Always have three limbs one foot and two hands or two feet and one hand in contact with the vehicle at all times when entering or exiting the cab or the area behind the cab Be certain you have a firm handhold and or stable foot position before transferring weight to that position For example do not start to put weight on a foot until you are certain your foot is properly on the step and will not slip when you transfer your weight Do not climb on top of the frame fuel tanks or storage boxes to make trailer hook ups If the vehicle is equipped with air fair ings do not use the side mounted fairing wind deflector brackets and braces as steps or grab handles Be certain that the grab handles are clear of snow mud ice or other sub stances that could make them slippery before using them Do not use steps or grab handles if they are slippery or damaged Be certain that all grab handles steps and related parts are in
15. Federal Law for Emission Control which adheres to EPA regulations No changes should be made that render any or all of the emissions control devices inoperative Should the owner operator wish to make any changes to the emission control de vices check with the state authority before making any such changes General Information 9 California Emission Control Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Volvo Trucks North America Inc VTNA are pleased to explain the emission control system warranty on your vehicle In California new motor vehicles must be designed built and equipped to meet the State s stringent anti smog standards Volvo Trucks North America Inc must warrant the emission control system on your vehicle for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your vehicle Your emission control system may include parts such as carburetor or fuel injection system and engine computer Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Volvo Trucks North America Inc will repair your vehicle at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This warranty is appliccable for a period of five years 100 000 miles or 3 000 hours of operation whichever first occurs If an emission related part of your veh
16. Push the control down and adjust the tilt of the seat cushion 3 Ride height adjustment Push or pull the control to change ride height 4 Lift the lever up to adjust the top part of the seat back 5 Push the lever down to adjust the whole backrest 6 The lumbar support is adjusted by turning the knob clockwise for firming and counterclockwise for slackening the support W8002387 7 The angle of the armrest is adjusted with the dial control on the underside of the armrest Seats Volvo Comfort Seat Adjustments When the vehicle is equipped with an electrically operated seat it is recom mended that the ignition key is removed when leaving the vehicle to avoid the risk of crush injury should an unautho rized person operate the control buttons Failure to do so can result in personal injury Seat and Seat Cushion The whole seat position fore and aft is ad justed with control 1 Push the control button forward or backward The total seat adjustment movement is approximately 7 5 in 190 mm The seat cushion position in relation to the back rest 2 is adjusted with control 2 Push the control button forward or back ward The total cushion adjustment movement is approximately 3 0 in 75 mm The seat cushion front tilt is adjusted with control 3 Press or lift the front part of the control to lower or raise the cushion front The whole seat height is adjusted with con trol 4 Lift or press the re
17. System diagnostic Cluster self test Bulb test 1 Select Bulb test 2 The telltale lamps light up for approx 5 seconds 3 Esc cancels the test and the menu Bulb test is shown again Changing Bulbs Changing the instrument cluster s telltale bulbs can be carried out from the rear side without the instrument cluster needing to be opened See page 95 for replacement information 147 148 Graphic Display Gauge test MENU System diagnostics Cluster self test Gauge test 1 Select Gauge test 2 The pointers move back and forth a few times between the end positions They stop at the mid point of the gauge before the test is complete then return to zero This is only a check that they can move i e that the gauge functions 3 Esc cancels the test and the menu Gauge test is shown again Display test MENU System diagnostic Cluster self test Display test 1 Select Display test 2 The display goes out lights up goes out In the odometer display all seg ments are shown then off back on off again and back to the normal display 3 Esc cancels the test and the menu Dis play test is shown again Graphic Display Buzzer test MENU System diagnostic Cluster self test Buzzer test 1 Select Buzzer test 2 On the display the name of the cur rent sound is shown at the same time as the sound is activated With the up down buttons you can switch be tween the different sounds Three different so
18. and no objects stuck between the wheels Check that both tires are of same type for example not mixed radial and bias type and that their circumferences are matched Check wheel bearing and hub no obvi ous leaking on outside or inside wheel Suspension Condition of springs leaf or air spring hangers shackles and U bolts Axle alignment Condition of torque rod arms If equipped with sliding axles check position and alignment Look for dam aged worn or missing parts all locks present fully in place and locked Flexible air tubing not cracked cut crimped or otherwise damaged Se cured against tangling dragging and chafing Brakes Condition of brake drums With brakes released look for a noticeable gap be tween lining and drum This check cannot be made if dust covers are in place Condition of brake hoses check for any chafing Check brake chamber mounting bolts and brackets Check slack adjusters and chamber push rod travel With brakes applied or released look for conspicuously dif ferent positions of the slack adjusters Check spring brakes Step 12 Rear of Trailer Area Lights and Reflectors Rear clearance identification and tail lights clean operating and proper color Reflectors clean and proper color Cargo Securement Cargo properly blocked braced tied chained etc Tailboard up and properly secured End gates free from damage properly secured in stak
19. only LOW and HIGH For proper operation see page 291 Instruments and Controls Heated Mirror Switch option The vehicle can be equipped with heated mirrors The switch turns on an electric heater element that is a part of the mirror glass The heater is self regulating and will keep a steady temperature after reaching operating temperature Both top and bottom mirrors are heated Turning the switch on activates a telltale in the instrument cluster The telltale will stay on until the switch is turned off W3003492 109 110 Instruments and Controls Pneumatic Switch Cluster The pneumatic switch cluster can have up to four optional equipment switches They regulate air flow directly to the following equipment Differential Lock Wheel and Interaxle Air Suspension Level and Fifth Wheel Slide To prevent accidental engagement each switch has a latch that needs to be pressed down before the switch can be operated W3002003 Differential Locks option There are differential locks available for each driving axle 4x2 or 6x4 or between axles on a 6x4 The differential lock elimi nates one wheel spin out on slippery surfaces and improves traction Each switch has a safety latch to prevent accidental en gagement When the lock is engaged a telltale lights up in the instrument cluster W3001991 A differential lock should only be used on Left Wheel diff lock a slippery surface and not when driving on Ri
20. page 311 for more information 288 Brakes Vehicle Speed Retardation Devices DANGER When operating a tractor bobtail with out a trailer or on slippery roads the engine brake switch must be in the OFF position Failure to follow this instruction can result in loss of vehicle control and serious personal injury or death A vehicle speed retardation device such as a Jake Brake C Brake Exhaust Brake etc is not intended to bring the vehicle to a stop A vehicle speed retar dation device is only intended to retard the vehicle speed under certain condi tions NOTE If a Volvo engine is equipped with a Volvo Engine Brake the brake will not operate with full power until the engine coolant temperature has reached 110 F 45 C NOTE It is normal for there to be a slight delay in the application of a vehicle speed retardation device When using devices of this type be sure to think ahead and ana lyze conditions in order to use the device properly Brakes Volvo Exhaust Brake The exhaust brake is standard on the Volvo D12 engine It is used to reduce wear on the brake linings The exhaust brake is most effective at high engine speeds 1 500 to 2 300 r min The exhaust brake is auto matically disengaged if the engine speed drops to or below 1 100 r min The exhaust brake works by containing the exhaust gases in the exhaust manifold thereby making the engine work against th
21. the cab Keep the engine exhaust system cab and cab ventilation system properly maintained It is recommended that the ex haust system and cab are inspected by a competent technician e At every engine oil change e Whenever a change is noticed in the sound of the exhaust system e Whenever the exhaust system under body or cab is damaged DANGER Do not breathe the engine exhaust gas It contains carbon monoxide which has no color or odor Carbon monoxide is a dangerous gas which can cause uncon sciousness or death N DANGER Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects or other reproductive harm To allow for proper operation of the vehicle ventilation system keep the inlet grille at the base of the windshield clear of snow ice leaves and other obstructions at all times Do not park the vehicle and let the engine run or idle for more than 10 minutes with the ventilation system control switch in the off position Even with the ventilation sys tem on running the engine while parked or stopped for long periods of time is not rec ommended Entry of carbon monoxide into the cab is possible with a poorly repaired damaged or corroded exhaust system or cab Do not run the engine in confined areas such as garages or next to a building any more than necessary The area must be properly ventilated When the vehicle must be s
22. the driver side wall A sleeper panel light is provided for the VN 770 model The light is located in the upper part of the panel and is operated by a switch located on the panel W3002332 W3002334 205 206 Cab Interior and Sleeper Storage Compartments N DANGER Heavy objects must be stored only in the outside storage areas or secured on the floor Cabinets and storage compart ments are designed for clothing and lighter personal effects only In the event of a collision heavy unsecured objects in overhead storage can come loose and cause severe personal injury or death to the driver or passengers All items within the cab must be secured before the vehicle is set in motion This includes but is not limited to drinks clothes books televisions etc In the event of a collision loose items could fly around inside the cab This could cause personal injury Front Overhead Storage There are several combinations of the over head storage compartments mounted over the windshield The compartments are split in the middle and they can be combined to cover the whole width of the cab or just over the driver The storage compartments have a maxi mum storage weight limit of approximately 18 lb 8 kg per section That is the limit covers each compartment section either left or right side Do not overload the cab suspension Make sure the weight distribution is equal in the cab Total load for the cab suspens
23. Bad device 13 Out of calibration ABS relay diagonal 2 14 Special instruction ABS dif 1 ASR valve i This is displayed when the airbag has stored ABS dif 2 ASR valve crash data or by the data concentrator when the engine shutdown output has been activated Speed signal input Warning light bulb 24 ASR light bulb 146 Graphic Display PPID Proprietary Parameter ID PPID Description Code 69 Buffered Idle Switch 70 Pedal Switches Supply 71 Cruise Control and Retarder Supply Switch 72 Accelerator Pedal and Retarder Supply Sensors 73 Accelerator Control 2 and Pri mary Tank Supply Sensors 75 Range Inhibitor Status Sole noid Valve 76 Brake Lamps Status Relay 71 Compressor Status Solenoid Valve 78 Interval Wiper Status Relay 9 Area Inhibitor Status Solenoid Valve Engine Brake Torque Percent 109 EPG3 Drive Stage Failure 121 MTE Engine Compressor Control Output Failure 122 VCB Engine Compression Brake 123 EPG2 Start and Warmhold 124 EPG1 Engine Brake 125 EOL Enable Failure 195 Proprietary Diagnostic Data Request Clear Count 196 Proprietary Diagnostic Data Count Clear Response Graphic Display Cluster Self Test MENU System diagnostics cluster self test Four sub menus are available e Bulb test e Gauge test e Display test e Buzzer test Cancel Test Press Esc in order to cancel the test Bulb Test MENU
24. Detector option Your vehicle may be equipped with a smoke detector The detector gives a warn ing signal when smoke particles enter it Other particles of the same type cigarette smoke dust and exhaust gases can also set off the alarm If driving in dusty environment or if the driver wants to smoke the alarm can be si lenced temporarily The alarm has two sound levels The first ten seconds the sound intensity is at 65 dB A and then it increases to 85 dB A The tone is pulsating It can be temporarily silenced by pressing the function button one the detector and one on the dash The alarm is now switched off for 10 minutes After that the detector goes back to normal operation When switched off a short sig nal is heard every 50 seconds The detector battery is monitored automati cally When the voltage is too low to ensure proper function a short signal is heard every 45 seconds To check the bat tery hold down the function button for approximately 5 to 10 seconds If the bat tery is functional the alarm sounds as long as the button is pressed The battery lasts for 1 to 2 years Its lifes pan depends on the number of alarms and high temperatures over 155 F 70 C About 1 month before the battery is fully depleted the alarm will start to sound in short bursts of sound The detector func tions normally during this time but change the battery as soon as possible The detector uses an ordinary 9 volt b
25. Electrical System 297 298 Electrical System Electronic Components Electronic circuits and components are designed to sense voltage differences smaller than 1 volt While static electric ity is not normally dangerous to humans it can seriously damage electronic cir cuits and components Circuit boards mounted in the instrument cluster may not fail immediately after being hit with a static discharge Rather they may work for a while and then fail for no apparent reason Therefore always work with proper grounding straps and antistatic mats around electronic components Welding N CAUTION Welding on the vehicle can damage the electrical system or components due to the high voltage and current spikes that normally occur when welding It is preferable to avoid welding on an as sembled vehicle However if any structure on or in contact with the vehicle must be welded follow the rec ommendations below Electrical System 299 If there are other ground cables con nected to the battery such as engine ECU etc disconnect those ground ca bles first then remove the main battery ground cable Electronic modules may be damaged when additional grounds are connected disconnected without the main battery ground connected Discon nect the main battery ground last Before welding on the vehicle electrical power needs to be disconnected and some components must also be disconnected e Disconnect both
26. Info Display instrument cluster graphic display MID 234 e SRS Airbag MID 232 e Cab controller Vehicle ECU MID 144 e Engine MID 128 Non specified system Reset all password Graphic Display 137 138 Graphic Display 1 The up down buttons are used to move the cursor in the list 2 SELECT confirms the selection of ECU or Reset all 3 During the time that each respective ECU is being called the display shows the text Data transfer in progress please wait 4 No faults in the chosen system Press Esc to return to the previous SENI No errors 5 Not responding to Non spec system Non spec syst MID 127 Not responding Press Esc to return to the previous menu 6 Ifthe chosen system does not respond within 5 seconds the following mes sage is shown in this example the engine has been called MID 128 Engine Not responding Fault codes are shown 1 If there is a fault code or codes the following is shown for example Line 1 Identification of ECU Line 2 Identification of parame ter component Line 3 Fault type identification 1 shows how many times the fault has been registered since the last resetting If no information is available for how many times the fault code has been registered only Active is shown the fault remains Or alternatively Inactive is shown the fault was there previously The arrow in the lower right hand corner is shown if ther
27. Malfunctions in any part caused by any of the following misuse abuse improper adjustments unless performed by a Volvo Trucks North America Inc dealer modifi cations alterations tampering disconnection improper or inadequate maintenance or use of fuels not recommended for the engine as described in the owner s manual 2 Damage resulting from accident acts of nature or other events beyond the control of Volvo Trucks North America Inc 3 The replacement of expendable maintenance items such as filters hoses belts oil thermostat and coolant made in connection with scheduled maintenance services once these parts have been replaced Any parts replaced under warranty before the first re quired replacement point are warranted for the remainder of the warranty period 4 Replacement items which are not genuine Volvo parts or not authorized by Volvo Trucks North America Inc Loss of time inconvenience loss of use of vehicle or engine or commercial loss 6 Any vehicle on which the odometer or hourmeter has been disconnected or the mileage or hours has been altered so the actual usage cannot be readily be deter mined 7 Any vehicle registered and normally operated outside the United States Nn 12 General Information WHAT IS COVERED BY THE EMISSION WARRANTY The following is a list of the items that are considered a part of the Emission Control Sys tems and are covered by the Emission Warranty when installed as original equipm
28. The upper bunks for the VN 610 660 and 770 are also hinged and can be raised out of the way The VN 610 and VN 660 use the safety bunk harness latch for holding the bunk up The VN 770 has latches on both sides of the wall that hold the bunk in position To release the latches pull the latch strap in the middle of the bunk under side Support the bunk before release so it does not fall unaided When the bunk is raised and latched make sure that the latches on both sides close and hold the bunk properly For more informa tion on bunk safety restraints see page 53 Wws8002021 re W8001885 Cab Interior and Sleeper 213 VN 660 Bunk Access To climb up to the upper bunk use the grabhandles and footstep mounted on the right hand side cabinet N DANGER Always have three limbs one foot and two hands or two feet and one hand in contact with the floor bunk or step at all times when entering or exiting the upper bunk Failure to follow this procedure can lead to a fall and cause severe per sonal injury or death Start the climb by grabbing the grabhandles with both hands Place the right foot on the bunk bottom to the right of the cabinet and the left foot on the upper step as shown Put both feet on the upper step and move the right hand to the upper bunk for sup port Swing the upper body into the bunk and sit down W0001769 214 Cab Interior and Sleeper VN 770 Bunk Access In the
29. VN 770 there are two ways of climbing to the upper bunk There is al ways a footstep available located in the passenger side cabinet Place the left foot on the footstep while holding on to the grab handle illustrated below Hold on to the handle in the middle of the bunk front edge and pull up into the bunk m i W8001886 The grab handle for upper bunk access is located on the cabinet E 1 W8001910 Cab Interior and Sleeper 215 Support the ladder with one hand while releasing the lock straps Failure to sup port the ladder may lead to the ladder falling out causing injury to leg or foot An upper bunk ladder is also available This is stored in its collapsed position be hind the passenger side cabinet To release the ladder unsnap the lock straps Support the ladder so it does not fall out unaided W8001888 The ladder unfolds out to provide a conve nient climb to the upper bunk W8001887 216 Cab Interior and Sleeper N DANGER Before using the ladder to enter the up per bunk make sure the free ladder leg is supported both at the upper catch and at the lower peg Failure to secure the ladder leg may result in a fall and seri ous personal injury or death When the ladder is folded out lift the outer leg and guide it into the catch that is lo cated on the upper bunk W8001890 Lower the leg down and place the peg into the hole at the bottom Test the lad
30. What Is Covered by the Emissions Warranty You are responsible for the perfor mance of all required maintenance on your new Volvo engine including maintenance or repairs needed due to severe operating conditions Volvo Trucks North America Inc will not deny a warranty claim solely because you have no record of maintenance However Volvo Trucks North America Inc may deny a warranty claim if your failure to perform required maintenance resulted in the failure of a warranted part Receipts covering the performance of regular maintenance should be retained in the event questions arise con cerning maintenance The receipts should be transferred to each subsequent owner of the vehicle with the emission warranted engine CUSTOMER ASSISTANCE Volvo Trucks North America Inc wishes to help to assure that the Emission Control Sys tem Warranty is properly administered In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control System Warranty you should contact Volvo Trucks North America Inc Warranty Administration 336 393 2000 The address and telephone number of each Regional Office is in your vehicle owner s manual If you need additional assistance or information concerning the Emission Control System Warranty contact Volvo Trucks North America Inc Warranty Adminis tration 336 393 2000 WHAT IS NOT COVERED BY THE EMISSION WARRANTY This warranty does not cover 1
31. action when Taosi the ASTOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked See page 126 for a listing of other telltales that are linked to the STOP telltale More than one message can be active at the same time When a new message is acti vated the new one is shown instead of the old A downward pointing arrow in the right hand corner of the display means that several messages are active Information Telltale General The yellow INFO telltale lights up when an abnormal status is detected by an elec tronic control unit A telltale or text or both are shown in the display in addition to the AINFO telltale For certain telltales a reference value is also shown The telltales are described starting on page 120 text messages are described starting on page 123 and combined telltale and text messages are described starting on page 125 Important When this telltale lights up the indicated fault should be checked at the next stop Information messages can be put on standby if other information needs to be ac cessed on the display See page 130 for information on how to acknowledge mes sages and how to recall messages Graphic Display AN iro T3008860 119 120 Graphic Display Telitales The yellow AINFO lights up
32. alarm clock 1 To set the alarm clock press SELECT when the menu ALARM CLOCK is shown in the menu TIME DIST Move the cursor to SET using the up down buttons Press SELECT If the speed during the setting exceeds 5 mph 8km h the function is can celled and the graphic display returns to the last active display in the ON po sition Set the hours with the up down buttons Confirm the choice with SE LECT Set the first digit in the minutes with the up down buttons Confirm the choice with SELECT Set the second digit in the minutes with the up down buttons Confirm the choice with SELECT Set the AM PM if the format is 12h with the up down buttons Confirm the choice with SELECT Move the cursor to ON using the up down buttons Press SELECT A symbol is shown on the right in the graphic display window s status bar in order to highlight that the alarm clock is activated Esc moves the highlight to the previ ous number or selection if there are any otherwise the setting is cancelled Graphic Display 167 ALARM 08 30 AM CLOCK 08 00 AM ON OFF SET T3008833 168 Graphic Display Ignition key in the off position When the ignition key is in the OFF posi tion if setting the alarm clock takes more than 30 seconds the time which has been entered then applies Switch off the alarm clock When the alarm clock goes off the word ALARM flashes the current time is shown and a warnin
33. always flow through them To have maximum air flow to the floor or to the windshield and cab door windows close the dash vents Heating and Air Conditioning 177 LUM 178 Heating and Air Conditioning Fresh Air Control The top slide lever is the Fresh Air Recirculation Control The settings can be anywhere from full fresh air intake to only recirculated air Settings can be chosen anywhere in between to give the desired flow of air W8001468 In the leftmost position the co fresh air inlet is closed All air is recirculated within the cab It can be used to heat up or cool down cab temperature quickly or to close intake from letting in odors etc with the intake air In the middle position there will TO be a 20 addition of fresh air to the 80 of recirculated air This position is well suited for use when the air conditioning is engaged so a minimum of warm or cooled air is lost through the evacuation vents while fresh air is still added to the cab fresh air inlet is completely open This is best used when heat is required wintertime and when defrosting or de icing In the rightmost position the as Heating and Air Conditioning Temperature Control The bottom slide lever is the Temperature Control which operates the coolant control valve In the leftmost position the flow of coolant is shut off by the control valve which means no h
34. area Test parking brakes by stopping on a 20 grade and applying the parking brakes The parking brakes shall hold the combined vehicle and trailer with out moving Pre Trip Inspection and Daily Maintenance 45 Daily Maintenance The following should be checked daily in addition to doing the pre trip inspection of the truck or tractor and trailer While checking the fluid levels visually in spect hoses pipes and their connections for signs of leakage Inspect the ground under engine transmission and rear axle s for signs of leakage Check coolant level in the coolant tank The level should be above the minimum mark shown on the side of the tank Do not remove the cap to the surge tank while the engine and radiator are still hot and under pressure Scalding fluid and or steam may be blown out under pressure if the cap is taken off too soon If the coolant level is low add more coolant to the tank so the level is above the minimum mark Coolant should be filled through the cap in the middle of the tank To prevent cooling system damage add only pre mixed coolant made up of 50 clean water and 50 antifreeze See the Operator s Manual Maintenance amp Engine for more detailed information N DANGER Before working on or inspecting a vehi cle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and ca
35. buzzer The engine may be started again after the key is turned off and then back on How ever it will only operate for 30 seconds unless the problem is resolved If the problem is allowed to persist seri ous damage to the engine may occur Always repair the cause of the problem before taking the vehicle into service again The engine could be forced to low idle within 30 seconds from when the light came on Pull off the road as soon as possi ble without being a safety hazard See page 126 for a listing on related mes sages that trigger this telltale Instruments and Controls 81 4 No Charge Telltale The No Charge telltale lights up red when a problem exists in the charging system or when there is no output from the alternator such as when the engine is not running T3008832 The No Charge telltale lights up dimly when there are several volts difference be tween the system voltage and the alternator output voltage The telltale shines brighter as the alternator output voltage drops For more information on the electrical sys tem see page 293 82 Instruments and Controls Main Instrument Section G Tachometer this page H Speedometer page 83 J Master Warning Telltale page 84 K Warning Telltales page 85 G Tachometer The tachometer is electrically driven by a signal from the engine Monitor the tachometer to guide correct gear shifting and to prevent engine overspeeding when de
36. continual relative movement of the seat with the cab the possible contact with the vehicle seat or other parts of the cab structure and the potential exposure of this safety belt to severe environmental con ditions make it crucial to inspect the seat belt system regularly It is recommended that the system be inspected every 15 000 miles 24 000 km or more often if the ve hicle is exposed to severe environmental or vocational conditions Any safety belt sys tem that shows cuts fraying extreme or unusual wear significant discolorations due to ultra violet ray exposure dusty dirty conditions abrasion to the safety belt web bing or damage to the buckle latch plate retractor hardware or any other obvious problem should be replaced immediately regardless of the mileage Once replacement of the safety belt has been determined necessary be certain that it is replaced only with a Volvo original re placement safety belt See your authorized Volvo Truck dealer for replacement Your Volvo safety belt system has been devel oped and tested specifically for heavy trucks Replace it only with the exact same design that the vehicle was equipped with If the inspection indicates that any other part of the safety belt system requires re placement the entire belt system must be replaced An installation guide is attached to every replacement system entitled Three Point Safety Belt Installation Guide There are separate safety be
37. cushions and pull the handle underneath the tabletop to release the latches Lower the table to its resting position Place the seat cushions toward the walls and then position the backrest cushions as illustrated W8001896 Press down on the cushions in the middle to form a mattress W8001897 220 Cab Interior and Sleeper Sleeper Compartment Sink A built in sink is available as optional equipment for the VN 770 sleeper model It is located on the left side in the cabinet be hind the driver The sink is mounted in the drawer space To pull out grasp the drawer lip and re lease the latch Pull out until the faucet can be raised without hitting the cabinet W8002162 Never run the pump without water in the freshwater tank The pump may be dam aged if run dry To operate the water pump there is a com bined valve and switch in the knob 1 on the base Turn on the 12V switch on the sleeper switch panel to the left of the tower cabinet then turn the knob slightly to start the pump Turn the knob further to increase water flow When the knob is turned fully back to rest position the pump will stop Make sure the pump is turned off before pushing the drawer in If the pump con tinues to deliver water overflowing W8002161 water can flood the cab floor In the bottom of the sink there is a spring loaded drain plug that is sealed by pressing down and twisting clockwise To release for lettin
38. customer and con nected to the data link CHECK ERROR IN MID 142 MID Message IDentifier controller To find more information on the data link diagnostic function see page 137 T3008860 Telltale Text The yellow INFO telltale lights up and information text together with a value is shown on the display The text contains in formation on where the fault has occurred and the value will show how much above or below the limit the current conditions are Transmission Oil Temperature If the transmission oil temperature becomes too high the AINFO telltale lights up automatically with the text HIGH This tell tale and text will come on when the oil temperature has been 210 F 100 C or above for 30 minutes or 250 F 120 C or above for 10 minutes NOTE If the temperature goes over 285 F 140 C a STOP message will be gener ated see page 129 Voltmeter The voltmeter value including the text TOO HIGH is automatically shown if the charging system voltage becomes too high Graphic Display 125 Let F nic uw 225 R AN info T3008860 EA TOO HIGH 17 V T3008860 126 Graphic Display Stop Telltale In the event of a serious fault the red ASTOP telltale lights up and the buzzer A N sTo sounds if the engine is on In addition to the AASTOP telltale a symbol or text or T9008861 both are shown in the display A reference value is also shown for certain telltales Tel
39. designed to sense voltage differences smaller than 1 volt While static electric ity is not normally dangerous to humans it can seriously damage electronic cir cuits and components Circuit boards mounted in the instrument cluster for example may not fail immediately after being hit with a static discharge Rather they may work for a while and then fail for no apparent reason Therefore al ways work with proper grounding straps and antistatic mats around electric com ponents Today s vehicles contain a high number of electronic devices It is very impor tant to exercise caution when working on a modern electrical system charging batteries or jump starting the engine To minimize the risk of any damage to the electronic components follow the proce dures below when work is being done to the electrical system NOTE Do not work on the electric system without proper tools and training Repair work to the electrical system must be done by trained professionals Your Volvo Truck dealer has the right tools and trained tech nicians Electrical System 293 Charging System An alternator with an integrated regulator is used to supply power to the vehicle electri cal system The charging system voltage should be checked periodically to prevent overcharging or undercharging the batteries and to detect any voltage drop in the wiring W3000978 Battery Box N DANGER When inspecting or cleaning batteries never smoke
40. do not come out lower the landing gear to relieve the pressure on the plungers Lowering the landing gear will also allow the fifth wheel to slide easier W9000205 334 Fifth Wheel Instructions Slowly drive the tractor forward or back ward to position the fifth wheel After sliding the fifth wheel to the desired position engage the slide locking plungers by moving the cab switch to the LOCK position press in the top part of the switch W8001459 Do not operate the vehicle if the plungers are not fully engaged and the trailer landing gear is not fully retracted Doing so may cause damage to the trac tor trailer and landing gear loss of trailer and personal injury Visually check to see that the slide plungers are fully engaged It may be nec essary to leave the trailer brakes locked and to move the tractor slightly to engage the slide plungers into the rail Wind up the trailer landing gear to its fully retracted position W9000205 Emergency Information 335 Towing Procedure General The driveshaft must be removed before towing the vehicle Failure to remove the driveshaft may result in damage to the transmission Remove the drive shaft from the rear axle before moving the vehicle unless it only needs to be moved a small distance for safety reasons When the transmission is driven from the rear wheels without the en gine run
41. drops to a normal level but then becomes too high again the warning is activated again Red STOP telltale The buzzer text message and the symbol can be acknowl A N sTo edged using Esc but are active again 10 seconds after pressing the button The red T3008861 STOP telltale remains lit the whole time Recall An acknowledged fault message can be re called i e be shown on the graphic display again MENU FAULTS 1 SELECT confirms the choice of the menu FAULTS The last acknowl edged fault message is shown If there is more than one message a down ar row is shown in the right hand corner 2 The up down buttons move the cursor between the current messages If an acknowledged fault message is still ac tive at the next occasion the ignition key is turned to the ON position this is shown as a non acknowledged message NO FAULTS is shown if there are no fault messages Graphic Display 131 132 Graphic Display Main Menu Set Up Mode The menu Set up mode has 14 sub menus where 6 are not protected by passwords and 8 are protected by passwords Language Mi F USgal or km C Clock format Contrast Backlight Night display Password is required see page 158 Default language Fleet limit r min Fleet limit speed Fleet fuel target Odometer setting Fleet ID Password config Language MENU Set up mode Language This setting of language applies only until the ignition key switch is turned o
42. for correct use W3000903 sth WHEEL LOCK W3000621 Wheel and Interaxle Differential Lock Telltales These telltales will light up yellow when the pneumatic switches for either the wheel or interaxle differential lock are turned on For the interaxle lock the telltale is acti vated by the switch For the wheel lock a switch in the axle turns the telltale light on only when the lock is actually engaged It turns the light off only when the lock is ac tually disengaged See page 311 for proper differential lock use Xe FE W3000904 Instruments and Controls 87 High Beam Telltale Any time the high beams are activated by the high low beam switch or the high beam flash switch the telltale lights up blue For r information on switching high low beam N see page 97 W3001303 Safety Belt Telltale The telltale lights up red each time the ig nition is turned on to remind the driver to fasten the safety belt It stays lit for 10 sec onds and then goes out automatically Before adjusting the safety belt make sure y the vehicle is stationary and that the seat W3000625 has been adjusted as required Do not at tempt to adjust the safety belt or seat while the vehicle is in motion For proper use of the safety belt see page 52 Parking Brake Telltale The telltale lights up red when the parking brake valve knob is pulled out The day time running light DRL function is also dependent
43. headlight switch Light in tensity can be varied from off to full brightness by turning the rheostat clockwise or counterclockwise Cigar Lighter To operate the cigar lighter press in the center until it stays in The heater element will heat up and pop the lighter out when it is ready for use The ash tray is located next to the cigar lighter 113 W8000947 W3000956 a Manun W3000959 114 Graphic Display Graphic Display Overview The display in the bottom left hand corner of the instrument cluster presents opera tional information to the driver The display menus and functions are selected with the controls on the right hand side of the steer ing wheel Certain information will be shown automatically e g warning mes sages that need immediate attention The display has a large number of main menus and sub menus used for selecting the correct functions This section describes each function how the display functions are accessed with the controls on the wind shield wiper lever and which actions are required by the driver when messages are automatically shown in the display 73010426 The information which is accessible varies depending on whether the truck is in a driving or non driving mode Certain func tions are protected by a password and are not shown until the correct password has been entered Password protected functions are described in Service Manual Instrum
44. holding the door at approximately 30 and in the fully open position at approximately 85 To close the door from the inside place the hand in the handhold and pull the door in N DANGER To lessen the chance of being thrown from the vehicle in case of an accident always lock the door and wear the safety belt while driving Failure to do so can cause serious personal injury or death if ROOTES involved in an accident Do not shut the door by pushing on the door panel Hard pushing may distort the metal in the door panel To close the door from the outside place the hand flat against the door lock area and push the door shut W8001853 22 Vehicle Access Cab Entry and Exit General DANGER Do not stand on the steps or any other part of the vehicle while it is in motion The steps and the back of cab access deck plates are only for entering exiting the vehicle and not for riding on Failure to heed this warning can result in seri ous personal injury or death Wearing shoes with soles that are dirty or wet increases the chance of slipping and falling Be careful when entering the cab with dirty or wet soles DANGER Steps are designed to be slip resistant and to provide a stable surface for entering or exiting the cab However ac cumulation of ice dirt lubricants etc on the steps can make entering or exit ing hazardous Always make sure the steps are free from slippery substances
45. jack for headphones This is provided for ay silent viewing of the TV When the headset jack is plugged in the speaker is cut out W3002431 Fuel Economy Driving 237 Fuel Economy General The absolute fuel consumption counted in miles per US gallon or liters per 100 kilo meters is determined by a large number of circumstances which can be related to one of the following main areas 1 Build specification and equipment 2 Service and maintenance 3 External environment 4 Driving habits Due to these factors fuel consumption can vary considerably within what is called normal fuel consumption Fuel consump tion can vary from over 10 mpg 20 L 100 km when driving empty on a nice and dry summer road to 3 5 mpg 70 L 100 km while driving with maximum permitted GVW with vehicle and trailer on a hilly and slushy winter road Build Specification and Equipment Whenever a vehicle is used for transporta tion its build specification equipment and gross vehicle weight have a decisive effect on both fuel consumption and performance The factors which have the greatest influ ence on fuel consumption are primarily driveline combination height of trailer or superstructure use of air fairings tire type number of wheels gross vehicle weight and accessories 238 Fuel Economy Driving Driveline Combination Engine transmission and final drive must be selected in such a way that the engine can opera
46. key fits in the door lock either way Insert the key and turn it 1 4 turn counter clockwise to unlock or clockwise to lock the door Key code at the end of keychain W0001231 NOTE The vehicle is delivered with 2 identical keys If more keys are needed order them through your Volvo Truck au thorized dealer The keys are laser cut and require a special machine for copying available through the dealer Record the key code and keep it in a secure place A new key can be made if the keys are lost The door locks are mechanically or electri cally operated The lock is activated by either the key from the outside or the door lock handle from the inside With mechani cal locks only one door can be locked unlocked at a time With electrical locks both doors will be locked unlocked by operating either the key or the inner door lock handle on either side To lock either door from the inside push the door lock handle forward The handle will stay in place indicating the door is locked It can be unlocked without opening the door by moving the door lock handle to the middle position No door can be locked while it is still open The door must be closed for the lock to work In the event of a power failure the electrical lock system reverts back to a me chanically functioning system W8001462 Vehicle Access 21 The door has a position lock that enables the door to remain open in two different positions An indented bar is
47. located on the turn signal lever To engage and set desired speed W3002499 1 Set the cruise control switch to ON 2 When the desired vehicle speed has been reached momentarily press in the SET or SET switch on the end of the lever 3 If the speed needs to be increased press the SET switch The vehicle speed will increase as long as the SET switch is pressed speed will not increase above the maximum pro grammed speed Release when the desired speed has been reached 4 Ifthe speed needs to be decreased press the SET switch The vehicle speed will decrease as long as the SET switch is pressed speed will not decrease below the minimum pro grammed speed Release when the desired speed has been reached NOTE The cruise control cannot be en gaged at speeds below approximately 30 mph 45 km h and engine speed below approximately 1 000 r min 266 Engine Start and Operation Disengaging The cruise control is disengaged if the brake or clutch pedal is depressed or if the cruise control switch is set to OFF If the ignition key is turned back to the acces sories position R the cruise control system will automatically be disengaged Resuming Vehicle Speed The previously selected cruise speed is re tained in the memory When the cruise control switch is pushed to the RESUME position the vehicle resumes the previously set speed providing vehicle speed is ex ceeding approximately 10 mph 15 km h
48. may impair the effectiveness of emission control systems If other than Volvo parts are used for maintenance owner should obtain assurances that suck parts are warranted by their manufacturer to be equiva lent to genuine Volvo parts However the use of other than Volvo replacement parts does not invalidate the warranty on other components unless such parts cause damage to war ranted parts Repairs and service covered by the warranty will be performed by an authorized Volvo Trucks North America Inc dealer at his place of business with no charge for parts or la bor including diagnosis using Volvo parts for the emission control system that requires replacement and is covered by the warranty and found defective In case of an emergency where an authorized Volvo Trucks North America Inc dealer is not available repairs may be performed at any available service establishment or by the owner using any equivalent replacement parts and Volvo Trucks North America Inc will reimburse the owner for such repairs including diagnosis not to exceed Volvo Trucks North America Inc s suggested retail retail price for the warranted parts and the labor rate appropriate for the geographical area and the tasks performed Replaced parts and paid invoices must be presented to a Volvo Trucks North America Inc dealer for reimbursement General Information 11 The emissions control parts covered by this Emission Control System Warranty are listed under
49. mounted free from damage and not leaking Trailer cord receptacle properly mounted free of damage plug prop erly seated and safety catch engaged to prevent accidental disconnect Air and electrical lines properly se cured against tangling snagging and chafing with sufficient slack for turns Step 10 Right Side of Trailer Area Landing Gear or Dolly Area Fully raised no missing or damaged parts Crank handle present and secured If power operated no air hydraulic leaks 1 eee mes 3 alera berries 18h A e Vane W0001361 Spare Wheel s e Carrier or rack not damaged e Spare wheel securely mounted in rack e Tire and wheel condition adequate for a Spare proper size properly inflated Lights and Reflectors e Trailer side clearance lights clean op erating and proper color e Reflectors clean and proper color Frame and Body e Frame and crossmembers not bent cracked damaged or missing e Proper placarding e Body parts not damaged or missing 42 Pre Trip Inspection and Daily Maintenance Step 11 Right Rear Trailer Wheel Dual Wheels One Or Two Axles Check condition of wheels and rims Especially look for cracks missing lockrings bent or broken spacers studs clamps or lugs Check condition of tires properly in flated no serious cuts bulges tread wear or any signs of misalignment valve stems not touching wheels rims or brake drums valve caps in place
50. mounted to the inside of the headliner connected with a coaxial cable to the cabinet VN 610 and VN 660 antenna is accessible in the cabinet A N CAUTION Do not pierce or drill through the head liner The TV antenna may be damaged W3002010 232 Communication and Entertainment Antenna Multiplexer 1 Cellular Phone Antenna Cable 2 Radio Antenna Cable 3 Left Side Antenna Communications signals that travel to and from the antennas go through the antenna multiplexer It is standard in the VN 660 and VN 770 and optional on other models Coaxial cables for the cellular phone CB radio and radio are included in the multi plexer system all using the same set of antennas W3002455 4 CB Radio Antenna Cable 5 Right Side Antenna The multiplexer is accessed through the lower dash panels Cable routing is as shown in the illustration above Use only genuine Volvo replacement parts for this multiplexer system standard antennas will give unsatisfactory performance The wind ings in the antennas are specific to this system different sections of the antenna are used for the cellular phone radio and CB Communication and Entertainment 233 Stereo Radio Stereo The radio is mounted in the right hand side of the dash Several models are available from a basic unit to top of the line In the VN 770 there is also a CD changer avail able which is controlled from the unit in the dash Depe
51. necessary If there is any doubt about the restraint system s effectiveness replace the entire safety belt assembly 56 Additional Safety Features The following maintenance guidelines de tail how to inspect safety belts and tethers for cuts fraying extreme or unusual wear of the webbing etc and damage to the buckle retractor hardware or other factors which indicate that safety belt system re placement is necessary Check the web wear at the buckle latch area The webbing must be closely exam ined to determine if there are any cuts fraying or extreme wear in the webbing Cuts fraying or excessive wear would indi cate the need for replacement of the safety belt system W8001406 The D loop web guide is an area where al most constant movement of the safety belt webbing occurs because of the relative movement between the seat and the cab This constant movement forms an area where wear will often occur The webbing must be closely examined to determine if there are any cuts fraying or extreme wear in the webbing Cuts fraying or excessive wear would indicate the need for replace ment of the safety belt system W8002478 Additional Safety Features 57 Check to make sure that the D loop web guide is rotating properly If the guide is not rotating properly the webbing will pull at the wrong angle through the guide ac celerating wear W8002477 If equipped check the comfort clip for cracks or pos
52. or death N DANGER Do not ride the brakes going down steep hills The brakes could overheat and lose their effectiveness Always choose a low gear before going down the grade and reduce speed to help control vehicle speed Losing the brakes going downhill can lead to an accident causing serious personal injury or death N DANGER Do not operate the vehicle when there is a malfunction in the compressed air sys tem An air brake system with leaks or other malfunctions may prevent the brake system from operating properly The vehicle should not be operated until the system is repaired and all brake cir cuits are working properly Failure to repair the system can lead to loss of control of the vehicle resulting in severe personal injury or death DANGER The brake system is a critical vehicle safety system For your safety and for those around you follow the recom mended preventive maintenance checks If any problems occur have them inves tigated immediately by an authorized service facility Failure to properly main tain the brake system can result in compromised brake efficiency and may lead to loss of control of the vehicle re sulting in severe personal injury or death DANGER Do not drive through deep water The brake system can be affected so the braking efficiency is less or the brakes pull the vehicle to the side This could lead to an accident leading to serious personal injury or death Bra
53. or expose batteries or the areas around them to sparks or flames The battery area may contain an explo sive gas mixture that can ignite causing an explosion leading to serious personal injury or death Battery posts terminals and related accessories contain lead and lead com pounds chemicals known to the State of California to cause cancer and reproduc tive harm Wash hands after handling to prevent personal injury Always wear eye protection when work ing around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion 294 Electrical System On a vehicle with air fairings batteries can be checked through the access door For full access the fairing needs to be removed To remove the fairing remove the two hex bolts in the corners of the step and the four screws to the cab The whole panel can now be removed W8001362 On a vehicle without air fairings the bat tery cover is also a base for the cab steps To remove the cover unhook the two rub ber latches and lift the cover up and out N DANGER When installing the battery cover make sure it is resting properly on the box before fastening the latches Faulty in stallation may cause the cover to shift when the steps are used which may lead to a fall causing serious personal injury or death There may be three or four batteries in stalled Always make sure the batteries are fastened properly in the box
54. or for any manufacturer or dealer knowingly to remove or render inoperative any such de sign after sale and delivery to the ultimate purchaser Specifically please note that no person may make such changes prior to the sale and Canada The same conditions that apply in the USA apply to Canada with one exception After the vehicle is sold to a retail customer that is the end user the jurisdiction controlling the emission control devices becomes the province in which the vehicle is licensed No changes should be made that render any or all of the devices inoperative Should the owner operator wish to make any changes to the emission control de vices check with the provincial authority before making any such changes delivery of the vehicle to the ultimate pur chaser and in addition no manufacturer or dealer may make take such action after sale and delivery of the vehicle to the ultimate purchaser The law provides a penalty of up to 10 000 for each violation Modifications such as reprogramming of the fuel system so the engine will exceed the certified horsepower or torque or re moving the mufflers are examples of illegal changes Changes should not be made to a certified engine that would result in an engine that does not match the configuration of an en gine model that is currently certified to meet Federal Standards Mexico The same conditions that apply in the USA apply to Mexico Refer to the Mexican
55. procedure on page 271 Failure to lock the gear lever properly into place can cause loss of control of vehicle leading to serious personal in jury or death W4001391 Luggage Compartment To gain access to the luggage compart ments there is a pull ring connected to the lock located at the lower rear corner of the cab door opening on each side Pull ring to unlock the door The lock has a safety catch that will hold the door in place even if the door is not fully locked To open door hold pull ring out while pulling the door out The door swings out from the bottom on hinges mounted on the top To assist in opening and to hold the door open there are two compressed gas cylinders mounted on each door The door will swing up by it self when pulled out a short distance and then released If the light switch is set on automatic the light will come on when the door opens Safety equipment and tow hooks are stored in the luggage compartments If equipped the sleeper heater and air conditioning unit is located in the passenger side luggage compartment Always place heavy objects in the lug gage compartment Sudden stops or sudden turns could cause personal injury if heavy objects fall from overhead stor age shelves Vehicle Access 29 W8000984 W8001073 W1000139 30 Vehicle Access Hood The hood is locked down by two latches one on each side of the back end of the hood The latches are op
56. reduces the background lighting 2 Confirm the choice with SELECT 1 off 2 parking lamps 3 high and low beam Cancel setting Press Esc in order to cancel the setting Graphic Display 135 Adjust lighting 136 Graphic Display Night display MENU Set up mode Night display 1 Select the menu Night display and the following diagram is shown on the display Night display Normal 2 With the up down buttons the setting switches between Normal and Re Reverse verse With the setting Normal the text is dark and the background light The setting Reverse makes the text light and the background dark This setting only applies when the headlights or parking lights are on 3 Confirm the choice with SELECT Cancel setting Press Esc in order to cancel the setting Main Menu System Diagnostic The menu System diagnostic has 3 sub menus which are not protected by a password and 1 sub menu which is pro tected by a password e Fault diagnostic e Cluster self test e Part number Password required see page 158 e Status test Fault Diagnostic MENU Diagnostic Fault diagnostic A list of the vehicle s ECUs is shown in the menu Fault diagnostic Each ECU is identified by a MID number Message IDentifier In addition a menu for resetting all the fault codes is shown For a list of common fault codes see page 143 ABS Brakes MID 136 Instrument cluster center module MID 140 e
57. the gauge pointers the operator is forewarned in the event of a pressure drop in either or both of the cir cuits See page 91 for more information W3003637 Before operating the vehicle check the air gauges which indicate air pressure They should not register less than 105 psi 725 kPa Maximum pressure at any time should not exceed 150 psi 1035 kPa 274 Brakes Both circuits are piped into a dual brake valve which simultaneously applies front and rear axle service brakes during each brake application In the event of a failure in either one of the circuits the other cir cuit becomes the emergency circuit for applying the brakes N DANGER The Master Warning Telltale and buzzer alerts of a dangerous situation Air pres sure is low and the remaining air volume may not be enough for repeated braking The emergency brakes may engage causing a wheel lock up loss of vehicle control and become a hazard to follow ing vehicles Bring the vehicle to a controled stop Failure to follow these precautions can result in loss of braking control and serious personal injury or death can occur as a result of a vehicle accident An important feature of the brake system is that an automatic spring brake application does not take place as a result of an air loss in only one of the two circuits In this case brake control remains in the foot brake valve In each air pressure gauge there is a warning light connected to a low p
58. the negative and positive battery cables Disconnect the negative cable first Reconnect the S positive cable first gt N T8006862 e Disconnect engine starter ground from the chassis This connection is located outside the left hand frame rail in the engine compartment e Disconnect the power harness and ve hicle interface harness at the engine electronic control unit EECU e If the vehicle is equipped with systems that have their own ECUs such as the vehicle ECU VECU ABS system air bag or some transmission systems disconnect each ECU at their electrical connection e Disconnect the electrical connections at the rear of the instrument cluster e Reposition or shield any parts that would be damaged by high temperatures 300 Electrical System e Attach the welder ground cable as close to the weld area as possible 6 or less e Do not connect the welder ground ca ble to the EECU or its cooling plate e Welding cables should not be allowed to lay on near or cross over any elec trical wiring or electronic component during the welding procedure e After finishing welding and the welded areas having cooled inspect wiring and components for possible shorts or damage In the event of a short circuit excessive current will be drawn when the batteries are reconnected causing more damage to the electrical system Do not weld on the engine or engine components Welding on the engine or
59. the side of the cab W3001355 100 Instruments and Controls Headlight Flash Switch option The headlight flash switch will momentar ily turn the headlights off when pressed The switch will return when released turn ing headlights on again This switch functions when either of Daytime Running Lights or low beam headlights are on W3002306 Sleeper Overhead Lighting VN 770 This operates the fluorescent overhead lighting in the VN 770 sleeper cab It is lo cated so the light can be accessed without entering the sleeper section of the cab The switch works together with the switch on the sleeper control panel see page 204 Depending on the position of the other switch switching on the light may have to W3001351 be done by pressing in the top or the bot tom part of the switch Instruments and Controls 101 Power Take Off There are two basic types of PTOs avail able engine mounted and transmission mounted The transmission mounted PTO is clutch dependent which means that opera tion can be regulated by depressing or releasing the clutch pedal This type of PTO should not be in use while driving The engine mounted PTO is direct mounted to the engine and is engaged with a bypass valve operated by the switch This type of PTO can be in use while driving NOTE If your vehicle is equipped with Autoshift and a Detroit Diesel engine the PTO telltale may blink when Autoshift is on and the transmissi
60. the vehicle application refer to the list of functions that is attached to the underside of each panel All fuses and relays are accessible under the top cover Fuses are standard Reset breakers are avail able as an option for some circuits If a fuse continues to melt or disconnect the circuit has a malfunction and must be repaired If a breaker disconnects the ignition or main switch must be switched off before the breaker resets W8000923 W30025 14 Failure to repair a malfunction in the electrical system can result in serious damage to electrical components and ve hicle fire Electrical System 303 The fuses and relays are all accessible un der the top cover on the dash W3002526 One type of fuse in the new electrical cen ter are termed mini fuses and require a puller tool to remove from the fuse block The puller tool is part of the Owner s Pack age To order a new puller specify part number 20378326 W3002525 Mini fuse puller tool 304 Electrical System Power Studs On the passenger side of the dash are power studs for a CB hook up These studs are standard equipment For a proper hook up use fork type connectors on the wires or use banana plugs If stripped wire ends are used make sure there are no wire strands that can bridge between the studs The red stud is the positive terminal and the black stud is the ground terminal Power from the studs
61. to select the same gear used to go up the grade 264 Engine Start and Operation High Altitude Operation Engines lose power when operated at high altitude because the air is too thin to allow burning as much fuel as at sea level For naturally aspirated engines this loss is about 3 percent per 1000 feet 300 m in crease in altitude above sea level Most turbocharged engines are rated for higher altitudes and will not lose as much power as a naturally aspirated engine An engine will produce excessive exhaust smoke at high altitude unless a lower gear is used Shift gears as needed to avoid ex cessive exhaust smoke Closely monitor the gauges during high al titude operation The thinner ambient air reduces the efficiency of the engine cooling system Engine overheat or cylinder dam age could occur if the engine is operated at full load for extended periods at high alti tudes in hot weather Downshift and reduce vehicle speed to reduce engine load when driving on long grades in these conditions This will help keep engine air intake mani fold and coolant temperatures within safe limits Engine Start and Operation 265 Cruise Control DANGER Do not use the cruise control in heavy traffic with ice snow on the road or dur ing other unfavorable conditions This may lead to a loss of vehicle control causing a vehicle crash and can result in personal injury or death Engaging The cruise control switches are
62. underside of the trailer W9000239 Select the UNCOUPLE position push down the latch and press in the bottom part of the switch on the suspension control switch to deflate the air springs W3001341 330 Fifth Wheel Instructions Wait about 30 seconds for the air springs to deflate W9000238 With the suspension lowered pull clear of the trailer and immediately select the RIDE position press the top part of the switch in on the suspension control This restores the suspension to operating height The vehicle must never be driven with the air springs deflated Damage to air suspension parts will occur if springs are not inflated properly W8001459 After the trailer is uncoupled the fifth wheel will be in the open position The op erating rod will drop and can be moved around freely W9000203 Fifth Wheel Instructions 331 For Tractors Without Air Ride Suspension Set the system park brake on the tractor Set the trailer brakes by pulling out the trailer air supply knob W5000921 Chock the trailer wheels Use two chocks both on the front and rear of the wheel on both sides of the trailer W9000263 Wind down the landing gear until it touches the ground and then give it a few extra turns in low gear Do not raise the trailer off of the fifth wheel Fold down or remove the crank handle and place it in the crank handle h
63. your vehicle under certain conditions 108 Instruments and Controls Several types of engine brakes can be in stalled or are standard on certain engines All are used to reduce wear on the vehicle brake linings Exhaust Brake Volvo Engine The exhaust brake is standard equipment on the Volvo engine It provides braking effect to the rear wheels by trapping the exhaust in the engine The switch for exhaust brake has two positions ON and OFF The exhaust brake is most effective at high be engine speed 1 500 to 2 300 r min For proper operation see page 289 Engine Brake Volvo Engine Optional The Volvo Engine Brake VEB is a com pression brake It works together with the exhaust brake to provide two levels of braking power The switch has three posi tions OFF LOW and HIGH With the switch in position LOW only the exhaust brake is engaged With the switch in posi tion HIGH both the exhaust brake and compression brake are activated For proper operation see page 290 W3002303 Jake Brake or C Brake Optional These engine brakes are similar in opera tion and are compression brakes Three power levels are available by engaging 2 4 or 6 cylinders in the braking for Cummins M11 only two power levels are available W3002303 The left of the two switches is the ON OFF switch The right switch is for selecting the amount of braking power with positions LOW MED and HIGH for Cummins M11
64. 100 km Acc 57 0 gal Trip overrevs 0 8 h Trip uneconomy rev s 0 4 h 156 Graphic Display NOTE If km and C has been se lected the consumption is shown in liters Trip fuel uneconomy rev s 8 5 gal Trip average speed 67 4 km h Trip overspeed 0 2 h Trip engine hours 3 0 h Trip idle time 0 4 h Trip idle fuel NOTE If km and C has been se lected the consumption is shown in liters 2 5 gal Trip PTO hours 1 3 h NOTE If km and C has been se lected the consumption is shown in liters 4 Ifthe transfer should fail the follow ing message is shown Cancel operation Press Esc in order to cancel the operation Graphic Display 157 Trip PTO fuel 20 4 gal Trip cruise 2 5h Operation failed 158 Graphic Display Main Menu Password Input Certain functions are password protected and there are two password levels for the display it is also possible to select not to protect functions with password which can be done by a Volvo Truck dealer 1 Workshop password 2 Owner password The two passwords give the user access to all password protected functions with one exception The workshop password does not give ac cess to the password configuration i e it is not possible to change the Owner password or the Workshop password with it The following menus are protected by pass word Defau
65. 107 Engine Break In 257 Engine Cold Start Volvo 249 Engine Idling 2 260 Engine Jump Start 297 Engine Operation 256 Engine Overspeed 259 Engine Serial Number Location Volvo Engine 2 4 4 4 g4 ees 18 Engine Shut Down System 258 Engine Start and Operation 244 Engine Start Procedure 244 Engine Stopping 247 Entering Behind Cab 25 Entering the Cab aa 24 Ether Start 2 amp eee ES 251 Exhaust Brake 107 Fastening Safety Belt 52 Fifth Wheel Instructions 316 Fifth Wheel Lock Telltale 86 Fifth Wheel Slider 320 Fifth Wheel Slider Operation 333 Fifth Wheel Unlocking 321 Fifth Wheel General 316 Fog light Switch 105 Folding Gear Lever 270 Foot Brake 215 Frame Alterations 7 Fuel Economy Driving 237 Fuel Level Gauge 90 Fuel Tank Caps 267 Fueling ae ae ee ee 268 Gauge Air Suspension Pressure 90 Gauge Brake Application Pressure 90 Gauge Brake System Air Pressure 91 Gauge Coolant Temperature 75 Gauge Drive Axle Oil Temperature89 Gauge Fuel Level 90 Gauge Oil Pressure 76 Gauge Pyrometer 74 Gauge Turbo Boost Pressure 77 General Information 1 Graphic Display 114 Graphic Display Controls 115 Graphic Display Overview 114 Graphic Display Telltales 117 H Headlight Bulb Chan
66. 127 W3003613 T3008861 E W3003614 T3008861 128 Graphic Display Text The red AASTOP telltale lights up and in formation text flashes on the display The buzzer sounds if the engine is running The text includes information about where the fault has occurred Specific data link fault Factory fitted equipment Not factory fitted equipment The following is shown if the customer has fitted equipment which is connected to the data link MID Message IDentifier controller To find more information on the data link diagnostic function see page 137 DANGER Failure to take necessary action when the ASTOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked STOP DATA LINK BRAKES STOP ENGINE FAILURE STOP FAILURE IN MID 142 Graphic Display 129 Telltale Text The red STOP telltale lights up and in formation text together with a value is shown on the display The text contains in formation on where the fault has occurred and the value will show how much above or below the limit the current conditions are Warning temperature transmission oil If the temperature of the transmission oil becomes too high the red ASTOP telltale is shown automatically with the tex
67. 20 154796 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 without the prior written permission of Volvo Trucks North America Inc Contents General Information 0 1 Information For the Owner 1 General Safety Information 3 Modifications to Vehicle cceeeeee 1 Exhaust and Noise Emissions 8 WOM WIRES A 16 Vehicle ACCESS siccssecsscississctscsccsissinaciccins 20 Cab Doors and Door Lock 20 Cab By and Bit acissicetsrditenceiens 22 Luggage Compartment lt iccisdisicsisacescns 29 DG rmh 30 Pre Trip Inspection and Daily Mainte RG 55 E E E 32 RARE ssseremene na 32 Pre Trip Inspection Quick List 33 Daily Maintenance ceeeceeeseeees 45 Additional Safety Features 50 Sael y Dels norssocrinnioisein 50 SRS ANDES science 61 Safety Equipment ioc ccccersaenrisnsenecesancars 68 VORAD Collision Warning System 69 Instruments and Controls 70 Dash Overview assess 70 Instrument Cluster Overview 71 Telltale Overview sccuciatiesincwmaanas 72 Graphic Display Telltale Overview 73 Left Instrument Section ee 74 Main Instrument Section
68. 3 Fifth Wheel Instructions 316 Fifth Wheel General Information 316 Fifth Wheel cccccssseeeeseseceeeoeees 319 Fifth Wheel Slider option 320 Unlocking the Fifth Wheel 0000 321 Trailer Coupling Procedures 323 Trailer Uncoupling Procedures 328 Operating the Volvo Slider 333 Emergency Information 335 Towing Procedure serscininessssn 335 Service Information 00 341 Service Assistance and Manuals 341 ES ict ee 343 Warning Label Information IMPORTANT Before driving this vehicle be certain that you have read and that you fully understand each and every step of the driving and han dling information in this Operator s Manual Be certain that you fully understand and follow all safety warnings It is extremely im portant that this information is read and understood before the vehicle is operated IT IS IMPORTANT THAT THE FOLLOW NOTE A note defines an operating proce ING INFORMATION CONCERNING dure practice condition etc which is LABELS BE READ UNDERSTOOD essential to proper operation of the vehicle AND ALWAYS FOLLOWED The following types of labels are used AN CAUTION throughout this manual A caution label directs the operator s attention to unsafe practices where per sonal injury is not likely but property damage could occur The caution label is in black type on a wh
69. BEFORE EN TERING OR EXITING THE CAB OR THE AREA BEHIND THE CAB 24 Vehicle Access Driver Side Entry Exit Open the door Place any hand carried items on the cab floor Grasp the right grab handle with your right hand and the left grab handle with your left hand Put your right foot fully on the bottom step and pull yourself up to the opening Slide hands up on the handles if necessary Put your left foot on the top step and step up Step into the cab with your right foot first To exit reverse the process Do not attempt to exit the cab while carrying any items in your hands On vehicles without side fairings al ways make sure that the battery box cover is securely fastened before step ping up Failure to fasten the cover may lead to personal injury Passenger Side Entry Exit Open the door Place any hand carried items on the cab floor Grasp the left grab handle with your left hand and the right grab handle with your right hand Put your left foot fully on the bottom step and pull yourself up to the opening Slide hands up on the handles if necessary Put your right foot on the top step and step up Step into the cab with your left foot first To exit reverse the process Do not attempt to exit the cab while carrying any items in your hands W0001223 i W0001228 Vehicle Access 25 Behind the Cab Entry When trailer air and electrical connections can not be coupled from the ground Fed
70. E The restraints for top and bottom bunks are different Each belt can only be installed to the correct bunk Additional Safety Features 55 Inspection DANGER Failure to properly inspect and maintain the safety belts can cause serious per sonal injury or death DANGER It is critical that any time a vehicle has been involved in an accident the entire safety belt system must be replaced in the vehicle which also includes the sleeper bunk restraints if they were in use at the time of the accident Failure to replace the safety belt system may re sult in serious injury or death N DANGER A damaged safety belt whether visibly damaged or not could result in serious personal injury in the event of an acci dent The safety belt systems should be replaced at least every five years N DANGER Do not bleach or re dye the color web bing because it may cause a severe loss of belt strength This loss of strength could allow the safety belt to break under stress thus resulting in severe per sonal injury or death Check the belts buckles latch plates re tractors anchorages and guide loops to ensure that they are working properly Look for loose damaged parts without disassem bling that could keep the restraint system from working properly If the safety belt retractor and hardware were in use during a collision they must be replaced The re straint system anchorage fasteners must be replaced if
71. GER Safety belts must be properly worn at all times by the driver and all passengers while the vehicle is in motion even if the vehicle is equipped with a Supple mental Restraint System SRS or air bag Failure to do so can result in seri ous personal injury or death in the event of a sudden stop or collision N DANGER Fasten the safety belt before starting to drive Trying to fasten the safety belt while the vehicle is moving may lead to an accident causing serious personal in jury or death Safety belt assemblies installed in this vehi cle meet FMVSS 209 Type 1 and Type 2 requirements They are recommended for all persons weighing over 50 lb 25 kg W8001834 A child restraint system should also be pro vided for each child weighing 50 Ib 25 kg or less It should meet the requirements of A WARNING FMVSS 213 Child Restraint System DEATH or SERIOUS INJURY can occur Carefully read and follow all manufac turer s instructions on installation and use eot as far back as possible ftom the ar bag Make certain the child remains in the re straint system at all times while the vehicle ALWAYS use SEAT BELTS and CHILD RESTRAINTS Vivo inda is in motion W8002741 Additional Safety Features 51 Safety belts must be worn by the driver and all passengers at all times Before adjusting or fastening the safety belt move the seat forward or rearward and adjust the seat height as necessa
72. MISSION OIL The transmission oil temperature is shown as in the diagram NOTE The temperature display starts showing only at approximately 150 F 65 C If the sensor data for Transmission oil temperature is not available the symbol is shown as well as the text NO DATA Information message Yellow INFO lamp If the temperature of the transmission oil becomes too high an information message is shown automatically with the text HIGH At the same time the yellow AINFO telltale under the display lights up Esc ac knowledges the information message For HIGH to display with the AINFO tell tale the transmission oil temperature must be 210 F 100 C for 30 minutes or 250 F 120 C for 10 minutes Yt F T3008831 Yet F T3008831 Yt F T3008831 ZN iro T3008860 170 F NO DATA HIGH 250 F Stop message Red ASTOP telltale If the temperature of the transmission oil becomes too high a flashing stop message is shown automatically with the text TOO HIGH At the same time the red ASTOP telltale under the display lights up and the warning signal sounds Esc acknowledges the stop message For TOO HIGH to display with the AASTOP telltale the transmission oil tem perature must be 285 F 140 C for 30 seconds Graphic Display 161 Let E TOO HIGH 285 F T3008861 162 Graphic Display Voltmeter MENU GAUGE VOLTMETER The battery charging voltage is shown as in the di
73. Operator s Manual VNL and VNM VOLVO Foreword This manual contains information concerning the safe operation of your vehicle It is extremely important that this information is read and un derstood before the vehicle is operated This manual also contains a considerable amount of information concerning the vehicle such as ve hicle identification Preventive Maintenance recommendations and a log for your service records Please keep this in the vehicle at all times In formation from other component manufacturers is supplied in separate manuals in the Owner s Package NOTE It is important that this manual stay with the vehicle when it is 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 not intended as a substitute for the Preventive Maintenance Service Manual and must not be regarded as such The National Highway Traffic Safety Administration NHTSA and Volvo Trucks North America Inc VTNA should be informed imme diately if you believe that the vehicle has a defect that could cause a crash injury or death Contact NHTSA by calling the Auto Safety Hotline at 1 800 424 9393 or 366 0123 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 TSP
74. They are automatically switched on when the parking brakes are released igni W3000953 tion must be on and will stay on until the parking brakes are engaged NOTE Do not use DRL at night or at any time visibility is reduced DRL is not a substitute for the main vehicle lights when driving at night Instruments and Controls 105 Driving and Fog Lights option Combinations of driving and fog lights can be mounted in standard locations in the aerodynamic bumper or from the underside of the steel bumper These are operated by a switch next to the headlight switch Fog and driving lights are wired so they are turned on only when the headlight switch is on Fog lights are used with the parking lights and the low beam headlights Driving lights are used with the high beam head lights Switching from low to high beam will automatically switch from fog lights to driving lights Driving and fog lights should be used when driving conditions require additional light ing The driving or fog lights should not be used in traffic where they might distract other drivers thereby creating a safety haz ard If the fog driving lights are added to the ve hicle as an accessory later on make sure the light controls are wired as described above W3000954 W3001356 106 Instruments and Controls Right Switch Cluster This switch cluster can hold up to six optional equipment switches Planned func tions are Marker Interrupt Tra
75. VOLVO DIESEL ENGINE THAT THE EMISSION CONTROL SYSTEM OF YOUR TRUCK 1 Is designed built and equipped so as to conform at the time of sale to all regulations of the U S Environmental Protection Agency and the California Air Resources Board applicable at the time of the manufacture and 2 Is free from defects in material and workmanship which will cause the emission con trol components not to function as designed for a period of use of 5 years or 100 000 miles or 3 000 hours of engine operation whichever comes first The 5 years 100 000 miles 3 000 hour warranty period shall begin on the date the vehicle is first delivered to the first retail purchaser or if the vehicle is placed in service as a demonstrator company vehicle prior to the sale at retail on the date the vehicle is the first placed in service The emission control system of your new Volvo engine was designed built and tested us ing genuine Volvo parts and the engine is certified as being in conformity with Federal and California emission control regulations Accordingly it is recommended that any re placement parts used for maintenance replacement or repair without invalidating this warranty the cost of such services or or parts however will not be covered under the war ranty except in an emergency situation A part not being available or a repair not being completed within 30 days also constitutes an emergency Use of replacement parts which are not of equivalent quality
76. age 114 for graphic display information There are telltales in the lower part Please refer to page 77 for telltale information el kdl obeole i e W3004396 Center Section The center section contains tachometer speedometer and odometer See page 82 for gauge information In the lower part there is a central warning lamp and telltales for different vehicle functions Please refer to page 85 for telltale information Right Section The right section can include forward and rear axle temperature gauges fuel level gauge application air pressure gauge front and rear brake air pressure gauges Vehicles with rear air suspension may have an air suspension pressure gauge See page 89 for gauge information There are telltales in the lower part Please refer to page 92 for tell tale information 72 Instruments and Controls Telltale Overview wr Nro N EX G 1 2 3 4 5 FI 20 A 4 8 9 Pad AC 19 1 Engine Preheat page 78 2 Yellow AINFO Light page 79 3 Red stop Light page 80 No Charge page 81 Left Turn page 86 Fifth Wheel Lock page 86 Wheel Differential Lock page 86 8 Axle Differential Lock page 86 9 High Beam page 87 10 Safety Belt page 87 11 Parking Brakes page 87 12 Tractor ABS page 88 NA wh 13 13 14 15 16 17 18 19 20 21 22 D H i 15 AN N 22 a 21 W3004406 Trailer ABS page 88 Air Suspension Leve
77. agram If the battery charging voltage becomes too low below 9 5 V the instru ment cluster will lose power T3008832 Information message Yellow INFO telltale If the battery charging voltage becomes too high the voltmeter s value is shown auto matically as well as the text TOO HIGH At the same time the yellow AINFO tell tale under the display lights up T3008832 ZN INFO 13 1 V TOO HIGH 17 9 V T3008860 Graphic Display 163 Main Menu Fuel Economy option Menu FUEL ECONOMY has 2 sub menus e AVG INST e LEG FUEL FUEL ECONOMY is chosen and then the up down buttons are used in order to change between the available sub menus AVG INST Fuel Economy MENU FUEL ECONOMY AVG INST AVG 9 For setting metric or English value dis plays see page 132 INST mE The following is shown on the display e Average trip fuel consumption AVG The value is presented numerically mpg TARGET and as an arrow above the bar The ar row s position shows the value For a short time after resetting the following is shown instead of the average fuel consumption e Instantaneous fuel consumption INST The value is presented numerically as well as in the form of a bar e Target trip fuel consumption TAR GET The value is presented as an arrow un der the bar The arrow s position shows the value This value is pass word protected see page 158 NOTE When idl
78. al fully depressed the ABS will control all wheels to provide steering con trol and a reduced braking distance Although the ABS improves vehicle control during emergency braking situations the operator still has the responsibility to change driving styles depending on the existing traffic road and or weather condi tions For example the ABS cannot prevent an accident if the driver is speeding or fol lowing too closely on slippery surfaces The ABS control unit contains a self testing program that is engaged each time the ignition is turned on The operator can verify the testing by listening for the ABS modulator valves actuating twice in series To increase the sound hold down the foot brake pedal when the ignition is turned on The self test is not finished and the telltale will stay on until the vehicle has started to move The wheel speed sensors are tested when the vehicle starts to move If they test OK the telltale will go out at approxi mately 7 mph 11 km h If any of the ABS telltales come on dur ing driving or do not go out after a short time after turning on the ignition take the vehicle to a Volvo Truck dealer to repair the ABS or brake system The ve hicle can still be driven with a problem in the ABS system However ABS will not be working and the standard braking system will be in effect W3000905 Brakes 287 Traction Control System TCS option The Traction Control System TCS uses
79. aler under part number 1089953 Use only this tool to change bulbs in the instrument cluster To remove bulb insert tool onto the bulb assembly rotate a 1 4 turn counterclock wise and pull the bulb assembly out of the cluster Insert a new bulb into the tool and install it into the cluster Rotate the bulb a 1 4 turn clockwise and pull the tool off of the bulb assembly NOTE The telltale area in the right part of the instrument does not use all spaces for active telltales These bulbs can be used for spare bulbs Lift up the instrument cluster and fasten the two screws at the top of the cluster W3000642 Instruments and Controls 97 Steering Column Switches Turn Signal Headlight Beam Change The turn signal is activated by the lever un der the left side of the steering wheel If the vehicle is equipped with a cruise con trol the controls for this are located on the turn signal lever See page 265 for more in formation about the cruise control The standard turn signal switch is self can celling It must be manually returned to neutral position after making a turn A self cancelling turn signal is available as an op tion For lane changes the lever does not need to be moved to a locking position Move the lever partway off the normal position until a resistance is felt The turn signal is now activated and the lever will return to normal position when it is released The headlight flash function is activa
80. also ac tivated From that time it will take 30 seconds before the engine shuts down In this time period find a safe place to pull off of the road After the engine has been shut down by the system the override will allow a restart of the engine for a period of 30 seconds This is so that the vehicle may be pulled off of the road if necessary The alarm will re main activated until repairs have been made to correct the problem The operator should not continually override the system as this can cause se rious damage to the vehicle s engine Engine Start and Operation 259 Engine Overspeed This vehicle is equipped with a diesel en gine and should not be operated in an area with a concentration of hydrocarbon vapors for example gasoline or diesel fuel fumes Be especially cautious of low lying or closed in areas The vapors may be drawn into the engine through the air intake and cause the engine to overspeed Hot carbon and other sparks may come from the ex haust system and cause an explosion and fire If the vehicle is in an area where hydrocar bon vapors may be present shut the engine off immediately if any abnormalities are experienced Do not leave it unattended N DANGER The diesel engine will operate on any fuel which enters the cylinder whether it is from the injectors or from the air in take system Therefore if any solvent is used to flush out the air cleaner element the engine may overspeed du
81. an ing capability and does not freeze in cold weather Total reservoir capacity is 3 3 gal lons 12 5 liters An indicator will appear on the graphic dis play and the yellow AINFO telltale lights up when the water fluid is low A 10 sec ond activation delay allows for fluid slosh W3003655 T3008838 Instruments and Controls 99 Left Switch Cluster This switch cluster has only one switch po sition permanently filled Other positions are for optional equipment The standard switch is for the Hazard Lights Other switches that can be located in this cluster are for Back of Cab Light Head light Flash Dome Fluorescent Light in VN 660 amp VN 770 and Power Take Off W3002002 Hazard Lights The hazard or four way warning circuit is activated by pressing in the bottom part of the switch The indicator light in the switch will flash in unison with the outside lights The hazard lights function independently from the ignition switch Activate this function only when the vehi cle is stopped where it might be a danger to other vehicles or to alert others of a problem that changes the traffic rhythm W3001350 Back Of Cab Light option Turn on the back of cab light by pressing in the bottom part of the switch The light will stay on until the switch is returned to off position Back of cab lights are available as a flush mounted light in the middle of the cab rear wall or as a high mounted light on
82. an continue to step down through Password Input i the list see the adjacent example 2 Pressing SELECT confirms the choice 3 Pressing Esc exits the chosen menu By pressing Esc repeatedly the cursor is moved successively back to the main menus 116 Graphic Display Changing Settings 1 The up down buttons increase or re duce the set values e g hours and minutes in the adjacent example 2 Pressing SELECT confirms the choice 3 If there are several settings to change in the same menu the cursor is moved to the next setting using the up down buttons e g the selection between ON OFF and SET in the adjacent ex ample 4 Esc moves the highlight to the previ ous number or selection if there are any otherwise the setting is cancelled Display Menus There are a number of main menus each with sub menus that lists functions avail able There are two types of menus Those that are available when the vehicle is in motion and those that can only be accessed when stationary Several non driving sub menus are only accessible with a password The password protected menus are not cov ered in this manual see page 158 While the vehicle is stationary there are 4 menus in addition to the 4 drive menus Also the menu TIME DISTANCE has one additional function while the vehicle is stationary ALARM CLOCK ON 08 20 08 00 OFF SET Non Driving Mode Menus Set Up Mode see page 132 Syst
83. and a telltale is shown in the graphic display describing in what component the problem has occurred Airbag The airbag SRS is described on page 63 The vehicle should be taken to an autho rized Volvo Truck dealer immediately if the SRS telltale stays on or lights up when the vehicle is being driven Instrument Cluster Overheating The symbol is shown when the temperature behind the instrument cluster is too high The instrument lighting becomes weaker and the indicators on the instrument show a minimal reading Lower the heat in the cab When the heat is reduced the instru ment functions will gradually be restored NOTE If the temperature is too high over a prolonged period the instrument cluster can be damaged Washer Fluid Level The telltale lights when the washer fluid is low ro T3008842 OFO T3008840 ner 7 I T3008838 Graphic Display 121 Air Filter Blocked option When the telltale lights the engine air filter e is blocked A blocked filter will cause higher fuel consumption and black smoke m To replace air filter see the Operator s Manual Maintenance and Engine T3008843 Too Cold for Engine Brake Volvo Engine Only Position 2 of the engine brake should not be switched on until the engine has become warm over 110 F 45 C If position 2 is O selected and the engine is too cold this symbol will be shown however VEB is T3009355 not activated Fault i
84. aphic Display 173 Too cold for en ine brake VEB Volvo engine only Position 2 on the switch must not be en gaged before the engine has reached operational temperature If position 2 is engaged and the engine is too cold this symbol is shown and a signal sounds when en gine braking is carried out However VEB is not engaged Fault in the pre heating a T3009913 T3008841 174 Heating and Air Conditioning General Three levels of the cab climate systems are available They can be identified by the ap pearance of the control panel The basic system is a heater and defroster unit only The heater unit has a rating of at least 40 000 Btu The manually operated heating and air con ditioning unit is controlled from the same panel as the heater system with the addition of a switch for turning the air con ditioning system on button with the snowflake symbol A variant of the air conditioning system can be added as an option This is called the Automatic Temperature Control ATC variant It is identified with the switch marked aut It allows all functions of the previous systems plus the ability to main tain the temperature in the cab as set by the driver The desired temperature is selected by the combination of the temperature con trol setting and the fan speed The air conditioning only operates when the engine is running Best performance from the air conditioning is achieved when all windo
85. aptation choices contact your Volvo Truck dealer Engine Start and Operation 263 Uphill Operation For best performance allow engine speed to reach the bottom of the rated torque range before downshifting Continue to downshift in this manner until a gear is reached that will maintain the desired speed Continue to operate at the rated torque if the vehicle will make it to the top without a downshift Begin upshifting as the grade of the hill decreases and the en gine begins to accelerate above 1600 r min Driving this way will give the best fuel economy and performance NOTE Allowing the engine to lug down to the end of maximum torque range is per missible if the vehicle is cresting the top of a hill However extended operation at en gine speeds below the maximum torque range usually 1100 to 1200 r min will raise exhaust temperature and cylinder pres sure This can lead to reduced engine life Downhill Operation A N CAUTION Do not exceed engine manufacturer s recommended maximum engine speed Engine damage can occur If equipped with an engine or exhaust brake do not exceed 2300 r min On a downgrade do not coast with the clutch pedal depressed or the transmission in neutral Select a gear that does not allow the engine speed to exceed the engine manufacturer s maximum engine speed rec ommendation Use the engine or exhaust brake and or the service brakes to control the vehicle speed A simple rule is
86. ar part of the control to raise or lower the seat 199 W8001831 200 Seats All the seat cushions are easily removed Grab the edge of the cushion not by the plastic base and pull up or out Back Rest The whole back rest angle is adjusted with control 5 Push the bottom part of the but ton forward or backward The back rest can be adjusted through 15 degrees of move ment The upper back rest angle is adjusted with control 6 Push the top part of the button forward or backward The upper back rest can be adjusted through 15 degrees of movement W8001915 W8001830 Seats 201 Back Rest Support In the middle of the back rest there are three inflatable cushions 1 2 and 3 that supports the lumbar region of the back Each cushion is controlled by an individual control Move each control 1 2 or 3 for ward to inflate or rearward to deflate the respective cushion On the sides of the back rest there are cushions 4 for the side support of the back Both cushions are controlled by con trol 4 Move the control forward to inflate or rearward to deflate cushions Seat Heater There are two heater elements 5 in the seat One in the seat cushion and one in the lower part of the back rest They are oper ated by the switch 5 on the side panel The elements are regulated by internal ther mostats and will therefore hold a steady temperature W8001829 202 Seats National Stationary Seat For t
87. at tery Always test the alarm after replacing battery 227 Control Signal Lamp Operation Flashes Silent every 45 s Alarm Flashes con Pulsating tinuosly sound Battery Flashes Beep every Change every 45 s 45 s Switched Flashes Beep every Off Mode every 10 s 50 s VOLVO LKH KHHK FKFJGFF FFJ JFFGD VGFL FMCND FKGFLLD LFJGKF FK FKGLF FL FMBJ MM MBGJHNJB DO NOT PAINT W8002479 228 Cab Interior and Sleeper VN 660 and VN 770 Side Windows The VN 770 has four and the VN 660 has two sleeper side windows that are used for ventilation When running the air condi tioning it recommended that the windows be closed In the event of hard rain the windows should be closed to prevent water from en tering the cab The windows also serve as emergency es cape exits In the event of an emergency aan kick the window open and climb out The windows are operated with a knob that is turned clockwise or counterclockwise to open or close the window Do not force the window crank mechanism in the fully open position The mechanism can be damaged trying to open the window beyond the stop position W8001856 Cab Interior and Sleeper 229 Cup Holders On the rear face of one or both sleeper cab inets are cup holders They normally are folded up To use fold down the base and fold up the support W8001881 There is also a cup holder in the middle of the dash To open press the
88. ation and empty by removing the inlet cap and tilting the tank up to let the waste water drain Flush the tank with fresh water Replace the inlet cap strap the tank into the cab and attach the drain hose W8002170 224 Cab Interior and Sleeper Miscellaneous Sleeper Equipment Sleeper Clock Alarm Clock Modes The clock has four modes that can be ac cessed by pressing the MODE button The modes that are not for clock or alarm func tion are described on page 190 T8007012 Display Mode Symbols To set the clock or to set the alarm use the MODE button to switch be tween functions The three symbols illustrated below can be shown on the display a Symbol showing that the alarm function is selected ni Symbol for the parking heater See page 189 for information it Symbol for the parking heater See page 189 for information e Cab Interior and Sleeper 225 Clock Function Setting Clock Press in the SET button for 3 seconds and the hour digits will start to flash Set the hour by pressing the up or down arrow button The time can either a 7 be set as an AM PM or 24 hour mode To go from the 24 hour mode to the AM PM mode continue to press one of the arrow buttons until the new mode is shown SET Accept the hour by pressing the SET button The minute digits will now start to flash a 7 v Set the minute by pressing the up or down arrow button Accept the minute by pressing the SET butto
89. be the result of using a cap without the pressure and thermal relief mechanisms In the case the cap is lost it must be re placed with a cap containing the same features 268 Engine Start and Operation Fueling Air is always present inside the fuel tanks entering mainly through the tank ventila tion With the air being heated up and cooled down condensation is formed and water is mixed in the fuel To avoid con densation when the vehicle is parked for longer periods fill the tanks up to 95 of capacity Do not fill more than that as the fuel needs to have room for expansion dur ing the heat of the day DANGER Do not carry extra fuel containers in the cab Fuel containers full or empty may leak explode or give added fuel to a fire Failure to follow this precaution may lead to a fire and serious personal injury or death DANGER Do not smoke while fueling the vehicle The glow from the cigarette can ignite the diesel fuel causing an explosion re sulting in serious personal injury or death Clutch and Transmission 269 Clutch General N DANGER Before starting the engine set the park ing brakes and place the transmission in neutral Failure to do so can result in un expected vehicle movement and can cause serious personal injury and death Do not allow the clutch to slip excessively This would cause excessive heat to be gen erated and the clutch will be damaged and bring on
90. brake or follow the me chanical spring brake caging procedures on page 339 NOTE The power steering does not func tion when towing a vehicle with a disabled W1000075 engine Emergency Information Towing Instructions If the vehicle becomes disabled it is very important to tow it properly Failure to do so can cause damage to the frame and body parts Follow the instructions below to avoid damage In the event that the vehicle cannot be reached to place the wrecker lift bar under the front axle use the tow eyes supplied with the vehicle The front tow eyes are used as a point at the front of the vehicle where the vehicle can be pulled N DANGER Do not use the tow eyes for raising the front of the vehicle the tow eyes can break Do not crawl under a vehicle sus pended by tow eyes Failure to follow these instructions can result in serious personal injury or death On day cab models the tow eyes are stored bolted to the back of the cab wall 337 W8000941 W8000943 338 Emergency Information On sleeper cab models the tow eyes are stored bolted to the back wall of the lug gage compartment wall The tow eyes are held in place when mounted on the front of the vehicle by trac tor pins These pins are stored in the tow eye mounting holes when not being used W8000934 When the vehicle is located properly lift the front and locate the lift bar under the front axle and secure U
91. button Set the minute digits the same way as the hour digits were set Accept the delay minutes by pressing the SET button The display will change to ON This means that the heater is ready to start when the set time has been reached If the heater is not to be started with the time delay press one of the up or down buttons and OFF is now displayed To alternate between ON and OFF press the up or down button which means that the time delay for the heater is engaged or disengaged Accept that the heater starts at the set time At the same time as the button is pressed the display returns to the clock function If the time setting was not completed the display returns to the clock function 30 seconds after the last button was pressed Heating and Air Conditioning 193 Heater Shut Downs e If the heater does not start within two 60 second start attempts a no start shut down occurs e Ifa flameout occurs after the heater has started the heater will attempt to restart If repeated flameouts oc cur within 10 minutes the heater will not restart e Overheat shut down will occur if there is a restriction of the heating air flow that is blocked inlet or outlet The automatic overheat switch will reset once the heater has cooled down e The blower motor is checked on start up and every 4 minutes Shut down will occur if the blower does not start or maintain proper speed If any of these events should occur the uni
92. can be obtained by contacting the respective manufacturer General Information 1 Establish a Preventive Maintenance Pro gram with the help of your local Volvo Truck dealer A Preventive Maintenance Program makes it possible to maximize the amount of time your vehicle is up and run ning resulting in longer component life This makes for a safer vehicle by reducing any mechanical failures due to poor mainte nance practices Various truck warranty coverage plans con tingent on application and weight class are available Please contact an authorized Volvo Truck Dealer for complete details Replacement warranty certificates for Volvo Trucks are available from Volvo dealers For trucks placed in service after August 1 2000 and operating in the USA and Canada Volvo dealers can print copies of the Standard Truck Warranty Certificate and the Premium Purchased Truck Cover age Certificate Copies are available in either English or Canadian French at the dealer communication system DCS web site Look in the Service Warranty folder NOTE Federal law requires manufacturers to notify owners of its products in the event of a non compliance to a Federal Motor Vehicle Safety Standard or if a safety re lated defect is discovered If you are not the original owner of this vehicle please notify us about the change in ownership at the address below or through an authorized Volvo Truck dealer This is the only way we will be able to co
93. causing skin burns from acid or serious personal injury or death Always wear eye protection when work ing around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion Charging the Battery High voltage machines that are used for work on the vehicle can do damage to the electrical system especially to its electronic components Welding or quick charging machines subject the wiring to excessive voltage which may often result in damage to electrical and electronic components anywhere on the vehicle Attempting to work on electronic com ponents without proper equipment can damage internal parts with static elec tricity Do not work on the electrical system with out the proper tools and training Repair work to the electrical system must always be done by trained professionals Your Volvo Truck dealer has the right tools and trained technicians Jump Starting the Engine If the batteries are discharged to the point where they do not have enough stored en ergy to start the engine they should be recharged using a low charge current not to exceed 16 volts If the vehicle needs to be started immedi ately use starting batteries Connect the batteries according to the information on the previous page DO NOT use battery chargers with boosting capability These produce a high voltage current that will cause damage to the vehicle electrical and electronic components
94. ch to increase decrease speed When the switch is released the en gine speed sets at current speed To resume engine speed 1 If the PTO function was interrupted resume set speed by pressing the PTO CC switch to RESUME and re leasing To deactivate PTO speed function 1 Set the PTO CC switch to the OFF po sition 2 Press down the service brake pedal 3 Depress the clutch pedal 4 Increase vehicle speed above PTO working range typically 5 mph 8 km h 104 Instruments and Controls Driving Light Switches Headlights The headlight switch controls parking lights and headlights It is a two position rotary switch turning on parking lights cab marker lamps and taillights in the first posi tion and turning on headlights in the second position To change between high and low beam pull the direction indicator lever all the way toward the steering wheel When a slight ni0 clicking sound is heard release the lever NOTE When switching from high to low beam for oncoming traffic release the lever as soon as the beam change is made Hold ing the lever up makes the headlight flash function stay engaged The headlight is combined into one aerody namic assembly The halogen bulbs are accessed from the rear of the assembly Headlights do not need to be checked for aim after bulb replacement For more infor mation on changing the headlight bulb see page 308 Daytime Running Lights DRL are stan dard
95. components mounted on the engine can cause serious damage to the engine ECU Electrical System 301 Battery Protection System option An electronic battery monitor Battery Lifeguard may be installed in the electri cal center This monitor will disconnect certain circuits if it senses that the battery voltage falls under a safe charging level Before disconnecting the monitor will sound a loud and distinct alarm alternating long and short beeps for approximately 60 seconds At the end of the alarm the monitor discon nects circuits to protect the batteries When the batteries are charged either through the vehicle alternator or a connected battery charger the monitor will automatically re store power to the disconnected circuits Disconnected circuits are connected to fuse positions F15 through 35 These circuits are W3002365 primarily feeding the sleeper area and headlights Unless the batteries are held at an elevated voltage for several hours they will only de velop a surface charge That charge will quickly go away and the relay will retrip 302 Electrical System Electrical Center The electrical center is located in the mid dle of the dash All the relays and fuses in the cab are collected here The cover panels are fastened with screws that can be turned with a coin Since the function of some fuses or relays may change for
96. ction Control TCS Exhaust or Engine Brake and Heated Mirrors W3000972 Marker Interrupt Switch The switch interrupts power to the marker lights when held down When released it will spring back to the ON position and re turn power to the marker lights W3001352 Traction Control Switch If the vehicle is equipped with a Traction Control System TCS there is a switch that can be used for increasing wheel spin This may be useful for decreasing the chances of getting bogged down when driving in heavy snow slush or muddy con ditions See page 287 for more information W3001336 Instruments and Controls 107 Exhaust Engine Brake NOTE It is normal for there to be a slight AX DANGER delay in the application of a vehicle speed retardation device When using a device of this type be sure to think ahead and ana lyze conditions in order to use the device properly When operating your tractor bob tail 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 may occur A vehicle speed retardation device such as Jake Brake C Brake Exhaust Brake etc is not intended to replace the service brake system on your vehicle nor intended to bring your vehicle to a stop A vehicle speed retardation device is only intended to retard the speed of
97. d Check to see that the trailer is at the proper height for coupling The leading edge of the trailer plate should initially contact the fifth wheel top plate surface about 8 in 200 mm behind the pivot point as the tractor backs under the trailer Raise or lower the trailer landing gear as required to obtain this position Attempting to couple with the trailer at an improper height could result in a false or improper couple and cause dam age to the tractor fifth wheel and trailer and possible personal injury Back under the trailer keeping the trailer kingpin centered in the throat of the fifth wheel After picking up the trailer STOP then continue backing until the fifth wheel locks firmly on the kingpin Stopping helps prevent hitting the kingpin too hard As an initial check pull forward to test the completeness of the coupling W5000713 W9000237 326 Fifth Wheel Instructions A direct visual check is required to en sure proper coupling Several types of improper couplings will pass the initial pull test Sound is not reliable Do not W9000286 take for granted that you are properly Failed trailer coupling coupled Get out of the cab and look Make sure the trailer kingpin is in the jaw slot and that the jaw is closed behind the pin The kingpin should not overhang the fifth wheel or be caught in the grease groove To verify that the kingpin is actually in the fifth wheel slo
98. d immediately if you believe that the vehicle has a defect that could cause a crash injury or death Contact NHTSA by calling the Auto Safety Hotline at 1 800 424 9393 or 366 0123 in the Washington DC area or by writing to NHTSA U S Department of Trans portation Washington DC 20590 Canada Refer consumer complaints to Volvo Trucks Canada Inc or to the Transport Canada Department of Public Complaints Recalls and Investigations Mexico Volvo Trucks of Mexico S A de C V should be informed immediately if you be lieve the vehicle has a defect that could cause a crash injury or death Contact Volvo Trucks de Mexico by calling or by writing to Volvo Trucks de Mexico S A de C V Prol Paseo de la Reforma 600 ler Piso 121 Col Santa Fe Pe a Blanca C P 01210 M xico D F NOTE For a listing of other contacts for information or help see page 341 1 800 424 9393 1 905 795 1555 01 800 90 94 900 Modifications to Vehicle Chassis Frame Frame side rails are heat treated No weld ing is permitted because structural failure may result Do not drill through either top or bottom flanges A warning label is also attached to the frame for information Drilling is permitted in the frame web in accordance with a specified hole spacing pattern Consult a Volvo Truck dealer to obtain approved hole spacing dimensions or refer to the Frame Rail and Cross Member Service Manual Frame rail an
99. d HIGH for Cummins M11 only LOW and HIGH For the exhaust brake to function the fol lowing must be in effect The switch is ON Vehicle speed over 7 5 mph 12 km h Engine temperature over 110 F 43 C Accelerator and clutch pedals fully re leased e Engine speed exceeding 1100 r min When the cruise control is engaged the ex haust brake automatically engages if the selected cruise speed is exceeded by ap proximately 5 mph 8 km h The exhaust brake is then disengaged when the speed has returned to approximately 3 mph 5 km h above the selected cruise speed For more information read the Jake Brake or C Brake operator s manual Brakes 291 W3002303 292 Electrical System Electrical System General Safety Guidelines A N WARNING Failure to repair a malfunction in the electrical system can result in serious damage to vehicle or fire Always let an experienced electrical technician perform repairs AN WARNING Always wear eye protection when work ing around batteries to prevent the risk of injury due to contact with battery acid A N WARNING Always replace fuses and circuit break ers with the same current amperage rating Never substitute a fuse with foil wire or nails Increasing fuse or circuit breaker ratings or substituting a fuse with foil wire or nails may result in electrical circuit overheating and possi ble fire and injury N CAUTION Electronic circuits and components are
100. d cross member nuts and bolts should be checked periodically and tight ened to the specified torque if necessary Frame Alterations Under no circumstances can the frame be cut and an extension piece added to in crease the wheelbase The only alteration allowed is wheel base shortening where the only change in the frame rail is a new hole pattern drilled for the new location of the rear suspension Welding In Vehicle Do not weld anywhere in or on the vehicle before disconnecting batteries all electronic control units ECU and instrument cluster See page 298 for more information Do not use oxy acetylene welding to repair cab panels Refer to the service manuals for specific information General Information 7 W7000519 Do not weld on any part of the frame or drill holes in the top or bottom flanges Serious structural damage could occur 8 General Information Exhaust and Noise Emissions General USA The Federal Clean Air Act Section 203 a 3 states the following concerning the re moval of air pollution control devices or modification of a certified engine to a non certified configuration The following acts and the causing thereof are prohibited 3 For any person to remove or render in operative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regula tions under this part prior to its sale and delivery to the ultimate purchaser
101. d mechanical condi tion and the necessary preparations are taken for cold weather operation ordinary cold weather will not cause difficulty in starting or loss of efficiency Cold weather operation does require changes in operating practices maintenance procedures lubrication and fuel Additions to the vehicle such as heated fuel filters fuel tank heater engine block heater win terfront etc can make winter operation easier Contact your Volvo Truck dealer for the correct accessories and information about installation If satisfactory engine temperature is not maintained increased engine wear will result in higher maintenance cost Acces sories should be designed to be easily disconnected when switching to driving in warmer weather so they do not affect the operation of the engine For cold weather operation follow these recommendations e When starting the engine in tempera tures below 32 F 0 C use engine lubricants of lower viscosity See the Operator s Manual Maintenance and Engine for more information e When the temperature is below freez ing make sure the concentration of antifreeze in the coolant is sufficient to prevent freezing See Operator s Manual Maintenance and Engine for more information Engine Start and Operation 253 e During cold weather give more atten tion to the condition of the batteries Test them frequently to ensure suffi cient power for starting A dead batt
102. der by pulling on it before climbing up W8001889 When folding the ladder back into stor age position make sure fingers are out of the way If fingers are on the inside section of the upright pole they may be pinched in the scissoring action of the folding ladder Cab Interior and Sleeper VN 660 and VN 770 Sleeper Table N DANGER Do not sit at the table when the vehicle is moving It is intended for use only when the vehicle is parked Passengers DO NOT SIT AT THE TABLE WHEN VEHICLE IS MOVING should be in the passenger seat wearing the safety belt or in the bunk with the bunk restraint attached Failure to follow these instructions may result in severe personal injury or death in the event of a sudden stop or accident An advisory label is attached on the rear face of the driver side cabinet To raise the table remove the cushions from the bunk and put them to the sides Release the latch by pulling the handle un derneath the tabletop Raise the table slightly 217 W8001898 W8001891 W8001893 218 Cab Interior and Sleeper Line up the latch pegs with the holes in the back wall W8001892 Push the table firmly into the holes Make sure the latches have caught properly by pulling out on the table W8001894 When the table is in place put the cushions in place to form a seat and backrest W8001895 Cab Interior and Sleeper 219 To lower the table remove the
103. dle set by the engine manu facturer By continuously pressing the switch engine speed will ramp up SET or down SET 6 When the desired engine idle speed is reached push and hold the SET and move the cruise control switch to the RESUME position at the same time and hold them in position for four sec onds Release the switches 7 Release the brake pedal to set the new idle speed If an error was made dur ing the adjustment procedure the default idle speed will be maintained 262 Engine Start and Operation Idle Shutdown Timer The idle shutdown timer can be programmed to shut down the engine after a specific engine idling time This programming cannot be changed by the operator however it can be changed using special tools For vehicles equipped with Volvo engines use VCADS Elite software application for vehicles equipped with Cummins engines use the Pro Link tool See your local Volvo Truck dealer for details The permitted idle time can be set to the following time interval Volvo 1 to 40 minutes Cummins 1 to 100 minutes Detroit 2 to 100 minutes When the idle shutdown feature is enabled the engine will shut down at the set time under the following conditions e Vehicle speed is 0 e Engine is running at idle speed e Coolant temperature is above 113 F 45 C e Parking brake is applied These are the standard choices when the vehicle is delivered For more information about other customer ad
104. down Load limit for the middle large opening storage unit is 3 Ib 1 5 kg for the side ee openings and 11 lb 5 kg for the center opening The smaller top and under upper bunk storage load limit is 3 lb 1 5 kg for the outer openings and 11 Ib 5 kg for the center opening The driver side storage upper part can be either a pantry type cabinet with doors see illustration or an open cabinet with netting covering the storage openings not illus trated The pantry has an optional 120 V electrical connection for a microwave oven The doors have latches that are accessed by hand from the bottom part of the door Load limits are 5 lb 2 5 kg for the top shelf 15 Ib 7 kg for the upper shelves and 33 lb 15 kg for the microwave shelf W8001865 210 Cab Interior and Sleeper The driver side storage bottom part can contain a refrigerator If a refrigerator is not delivered with the vehicle it is fully pre pared for installing one at a later time g The passenger side storage upper part is prepared for TV and video There is also general storage above There is an optional 120 V electrical connection available for accessories Load limits are 5 lb 2 5 kg for the top shelf 15 Ib 7 kg for the upper shelves and 33 lb 15 kg for the TV shelf W8001862 The passenger side storage bottom part is a clothes cabinet It is equipped with doors that latch closed when shut W8001867 Cab Interi
105. driving The load limit for the cabinets is 10 lb 4 5 kg per shelf or 30 Ib 14 kg total per each cabinet W8001394 W8001395 W8002332 208 Cab Interior and Sleeper In both the VN 610 and VN 660 access to the luggage compartment is made by lifting the lower bunk The bunk support is also the cover for the luggage compartment The bunk support is counterweighted with gas springs that make lifting easy To open release the latch mechanism and lift the bunk Remove heavy items from top of the bunk before opening W8002021 The VN 610 front overhead roof storage offers extra storage for smaller items Load limits are 3 lb 1 5 kg for the side com partments and 5 lb 2 5 kg for the center compartment W8001096 The VN 660 front overhead roof storage is the same as for the VN 770 Load limits for the right and left sections are 5 lb 2 5 kg for upper shelf and 15 1b 7 kg for lower shelf Load limit for the center section side shelves and the center shelf is 3 Ib 1 5 kg each W8001861 Cab Interior and Sleeper 209 VN 770 Storage Rear wall storage in the VN 770 varies de pending on if an upper bunk option is chosen or not The smaller storage units are also stereo speaker holders and mountings for the bunk restraint latches Each opening is covered with a netting for keeping stored items in place The top netting bar is spring loaded To access the opening press the bar
106. e back pressure This provides a retarding force on the drive wheels The exhaust brake is operated by a two position switch in the right hand switch cluster For the exhaust brake to function the following must be in effect e The switch is ON e Accelerator and clutch pedals are fully w3001324 released e Engine speed exceeds 1 100 r min When the cruise control is engaged the ex haust brake automatically engages if the selected cruise speed is exceeded by ap proximately 5 mph 8 km h The exhaust brake is then disengaged when the speed has returned to approximately 3 mph 5 km h above selected cruise speed NOTE For both exhaust and engine brakes use a one gear driving strategy when going downhill to keep engine speed up for effective braking for example up hill 7th gear and downhill 6th 289 290 Brakes Volvo Engine Brake option The Volvo Engine Brake VEB has a higher braking effect than the exhaust brake The engine brake is most effective at high engine speeds 1 500 to 2 300 r min It is automatically disengaged if engine speed drops below 1 100 r min The engine brake function is operated by one switch in the right hand switch cluster It works together with the exhaust brake to provide two levels of braking power The switch has three positions OFF LOW and HIGH With the switch in position LOW only the exhaust brake is engaged With the switch in position HIGH both the exhaust bra
107. e bulb by bending up the lock tabs and pulling back at the same time Turn the lock ring counterclockwise and remove Pull out the bulb NOTE When removing the new bulb from the box do not touch the glass with fingers or anything that may put grease on the glass surface Install the bulb and line up with the loca tion tab by turning it and then push it in until fully seated Install the lock ring Push the terminal back on Check that the rubber seal is clean and then install cover and snap the clamps over it Make sure to use the correct replacement bulb W3002422 W3002424 Power Steering General The power steering consists of an inte grated gear and hydraulic power cylinder and a power steering pump with fluid con tainer The pump driven by the engine provides hydraulic pressure to the power steering If the engine is not working the steering is only manual With the power steering not working the effort required to turn the steering wheel is much greater than with power assist If the power steer ing assist fails bring the vehicle to a safe stop Do not drive the vehicle until correct ing the cause of the problem N DANGER Do not drive the vehicle without power assisted steering When the power assist has failed the effort to turn the steering wheel is much greater especially in sharp turns or at low speeds This can cause an accident and lead to serious personal injury or death While o
108. e event of a serious collision above a certain level where the angle of impact crash severity speed and nature of the object in volved in the collision all play a part in whether or not the airbag is activated The system consists of a gas generator sur rounded by the inflatable airbag In the event of a sufficiently violent collision a control unit activates the gas generator ig nitor and the airbag inflates To cushion the impact the airbag deflates when com pressed This also releases some non toxic smoke into the cab The entire sequence from inflation to deflation of the airbag takes a few tenths of a second Never attempt to drive with a deployed airbag With the bag hanging out of the hub of the steering wheel the truck may be more difficult to steer In addition other safety systems may be damaged Continuous exposure to the smoke and dust created during the deployment of the airbag can cause irritation to the skin and eyes T8006849 T8006855 Additional Safety Features 63 The SRS system is continually monitored by the control unit A control unit is mounted on a bracket above the engine cover which detects deceleration The con trol unit also contains a standby power unit which can supply the system with power for a short time should the normal supply be broken T8006857 If the control unit detects a sufficiently vio lent deceleration collision the system is activated The ga
109. e Emission Control label is located on the left end of the dash It is the Owner s responsibility to maintain the vehi cle so that it conforms to EPA regulations Refer to page 14 for a listing of what con stitutes tampering with the Noise Emissions Control W0001458 18 General Information Components The Volvo D12 engine serial number is lo cated on the rear left side of the cylinder block There is also a label on the engine elec tronic control unit that shows the engine serial number The Volvo D7 engine serial number is lo cated on the rear left side of the cylinder block There is also a label on the rear valve cover that shows the engine serial number esl SLLLN D7 000777 W2002707 General Information 19 The rear axle model and serial number is located on the right side of the transfer gear housing on the tandem front axle It is lo cated on the left side of the differential housing on the tandem rear axle and on the right side of the single axle AXLE TYPE PART NR REAR AXLE DIFF ASSY FABR NR REAR AXLE DIFF ASSY RATIO W4000894 20 Vehicle Access Cab Doors and Door Lock The cab door is unlocked with the same key used for the ignition lock Keys can be made to fit only one vehicle or all the vehi cles in a fleet of Volvos A tool for changing bulbs in the instrument cluster is included on the keychain The
110. e cases coolant and inlet manifold temperatures must also be care fully monitored and controlled If a winterfront is used it must conform to these specifications e The grille coverage should be such that airflow through to the charge air cooler is at a uniform rate over the entire area This means that a single small opening in the winterfront is not acceptable e Air passage must be distributed evenly across the grille and no more than 85 can be covered Please see your local Volvo Trucks dealer for Volvo recommended winterfronts NOTE If there is engine or related dam age that can be traced to an improperly used winterfront the warranty is no longer valid for those parts 256 Engine Start and Operation Engine Operation General Proper operation driving techniques and maintenance are key factors in obtaining the maximum life and economy from a modern turbocharged diesel engine This section has operational information about the components that make up the engine For the best operation economy see Fuel Economy page 237 When changing gears avoid lugging to extend engine life When the engine is op erating at full throttle and maximum governed speed cannot be reached or main tained the engine is lugging When approaching a hill requiring more power it is necessary to downshift the transmission as the vehicle goes into the grade Acceler ating to the governed engine speed will give additional po
111. e is more than one fault code The up down buttons move the cursor and the next fault code message is shown To reset codes a password must be entered see page 158 2 If more than 20 fault codes messages are available for the chosen ECU the 21st message will be To see those messages that are not shown earlier messages must be reset see above The fault codes are pre sented in text format but the user can also choose to have the fault codes presented numerically if a fault code or ECU is not recognized by the sys tem they will only be presented in numeric format Graphic Display 139 Engine Coolant temperature Value too high Active gt 1 ie Engine Too many error Messages 140 Graphic Display Numeric or text 1 Press SELECT when there are fault codes and the following menu is shown Select numeric or text format the function Reset will only be shown when the correct password has been entered see page 158 When Text has been selected the fault codes are shown according to step no 1 page 139 When Numeric has been selected the fault codes are shown with numbers MID Identification of ECU PID Identification of parameter PPID Volvo unique identification of parameter SID Identification of component PSID Volvo unique identification of component FMI Identification of fault type s 1 shows how many times the fault occurred since the last resetting If there i
112. e key on to the start position Release key as soon as the engine has started For the Volvo engine the pre heater can be engaged to help starting in cold temperatures For switch func tion see page 248 If at start up or thereafter the oil pressure gauge indicates any drop in oil pressure the engine must be shut down immediately Failure to stop the engine may cause major engine damage W3000902 When the engine has started it takes a while to send lubricating oil to all bearings and shafts and between pis tons and liners Wait for the oil pressure gauge to settle at a normal level then bring engine speed up grad ually Increase speed as it warms up Check all gauges during warm up 7 During warm up apply load gradually until the oil temperature reaches 140 F 60 C To start a loaded vehicle the minimum coolant temperature must be approximately 120 F 50 C Engine Start and Operation 247 Stopping the Engine Allow the engine to slow down and idle for 3 to 5 minutes before shutting it off This allows the turbo to slow down and the cooling system to dissipate the engine heat Switch the engine off by turning the igni tion key to the O or OFF position Shutting off an engine immediately after high speed or full load operation can damage the turbo and cause heat stress in the engine Always let the engine idle for 3 to 5 minutes before shutting it off 248 Engine Start and Operation Igniti
113. e laws the appropriate Federal or state agency should be contacted Volvo Trucks North America Inc reserves the right to make changes at any time or to change specifications or design without no tice and without incurring obligation SLEEPER 770 VN cab types W0001619 General Information 3 General Safety Information Operating the Vehicle Every vehicle including heavy duty vehi A DANGER cles has blind spots The size of blind spots varies from driver to driver and from situation to situation As a skilled profes sional driver you are in the best position to avoid accidents in turns lane changes or other maneuvers Volvo Trucks North America Inc provides standard equipment such as cabs windshields window sizes and mirrors preferred by most owners and drivers under most conditions and in most applications Never try to operate or work on this vehicle while under the influence of al cohol Your reflexes can be affected by even a small amount of alcohol Drink ing and operating this vehicle can lead to an accident causing serious personal injury or death However due to differences in the size of drivers their seating positions the way that they use and operate their vehicles per sonal preferences and other factors no combination of mirrors and other visibility enhancement devices will eliminate all blind spots in every situation The safe operation of this vehicle is up to yo
114. e parking brake spring tension is suffi cient to hold a fully loaded vehicle on maximum grades permitted on modern highways provided the brake drums and linings are in good condition and the brakes are properly adjusted Do not use the spring parking brakes if the service brakes are hot such as after descending a steep grade Also do not use the spring parking brakes during freezing temperatures if the wheel brakes are wet To do so could damage the brakes if hot or may cause them to freeze during cold weather If the brakes are wet drive the vehicle in low gear and lightly apply the brakes to heat and dry them Allow hot brakes to cool before using the parking spring brakes 282 Brakes Do not set the vehicle in motion if the parking brake is engaged An alarm will sound if you do Movement of the truck while the parking brake is set can cause brakes to overheat This may lead to wheel end fire To avoid overheating make sure both parking brake knobs are pushed in before driving off There are several ways to determine if the parking brakes have been set By pulling out the yellow knob e An audible rush of air will be heard when the parking brake knob is pulled The air exhausts from the park brake valve itself and from the spring brake chambers on the rear axle s e A black ring around the base of the yellow control knob will be seen e There will be a fluctuation in the air pressure gauge needles e Y
115. e pockets Canvas or tarp if required properly latched down to prevent water damage tearing billowing or blockage of either mirrors or tail lights Rear doors securely closed latched or locked required security seals in place Underside guard in place not cracked bent or broken Pre Trip Inspection and Daily Maintenance 43 NOTE Refer to the trailer manufacturer s manual for specific information on the trailer checks Step 13 Left Rear Trailer Wheels Area Dual Wheels One Or Two Axles Check condition of wheels and rims Especially look for cracks lockrings missing bent or broken spacers studs clamps or lugs Check condition of tires properly in flated no serious cuts bulges tread wear or any signs of misalignment valve stems not touching wheels rims or brake drums valve caps in place and no objects stuck between the wheels Check that both tires are of same type for example not mixed radial and bias type and that their circumferences are matched Check wheel bearing and hub no obvi ous leaking on outside or inside wheel Suspension Condition of springs leaf or air spring hangers shackles and U bolts Axle alignment Condition of torque rod arms W0001361 e If equipped with sliding axles check position and alignment Look for dam aged worn or missing parts all locks present fully in place and locked e Flexible air tubing not cracked cut crimped or otherwise da
116. e pressure the springloaded lever will be pushed up out of the locked position W4001389 Clutch and Transmission 271 e Lift and fold the gear lever straight back parallel with the seat It will come to rest in the folded position NOTE If the lever is not moved straight back it may not be able to travel the full distance W4001390 Locking Gear Lever To lock the gear lever in place move it from the folded position forward until it is upright Press down on the knob and twist clockwise until the knob is lined up straight N DANGER Make sure that the gear lever is securely locked in position before taking the ve hicle on the road Failure to do so can cause loss of control over the vehicle leading to an accident with serious per sonal injury or death 272 Brakes Brakes Brake Safety Information N DANGER Do not inspect or adjust parts or compo nents in the brake system without setting the parking brake placing the transmis sion in neutral and securely chocking the wheels If the vehicle is not secured to prevent uncontrolled vehicle movement it could roll and cause severe personal injury or death DANGER Do not use replacement parts anywhere in the brake system unless it conforms exactly to original specifications A non conforming part in your vehicle s brake system could cause a malfunction lead ing to loss of control of the vehicle resulting in severe personal injury
117. eal 2 4 6 8 10 12 W3003646 1 Left Turn Telltale page 86 8 Anti Lock Brake System Tractor or Truck Telltale page 88 2 Fifth Wheel Lock Telltale page 86 9 Anti Lock Brake System Trailer 3 Wheel Diff Lock Telltale page 86 Telltale page 88 4 Interaxle Diff Lock Telltale page 86 io AS Syaemreliiale 5 High Beam Telltale page 87 page 88 6 Safety Belt Telltale page 87 11 Mirror Defroster Telltale page 88 7 Parking Brake Telltale page 87 12 Right Turn Telltale page 86 NOTE All telltales may not be used in all vehicles The telltale strip is located below the tachometer and speedometer A yellow cau tion telltale indicates that there is a system or component in the vehicle that requires the operator s attention A red warning tell tale indicates that there is a system or component that should be checked before the vehicle is driven any further 86 Instruments and Controls Left and Right Turn Telltales This lights up green when the turn signal is activated and blinks in time with the out side turn signal lamps An audible signal also sounds in time with the telltale A sin gle short beep is heard when the telltale lights up 5th Wheel Lock Telltale This telltale will light up yellow when the pneumatic switch for the 5th wheel slide lock is turned on It will stay lit until the switch is turned to the off position again See the 5th wheel uncoupling section on page 333
118. eat from the climate unit The heat will increase the further to the right the control is moved The temperature control should be used as a thermostat together with the fan speed to dial in the desired temperature when using the air conditioning The desired tem perature is selected by the combination of the temperature control setting and the fan speed For the ATC version the tempera ture is automatically maintained to where the control was set If needed the control can be moved to a new setting without turning the ATC off Using the heater on days when the outside temperature is low but there is direct sun light heating through the windows the air distribution control should be set in the center position air directed to the floor and the air vents open and at the same time the temperature control should be set around the middle position Warm air is then distributed so that it is warmest at the floor and cooler air is distributed via the air vents on the dash When the temperature control is set in one of the end positions the temperature at the floor vents and the air vents is the same 179 W8001469 180 Heating and Air Conditioning A C Control When the vehicle is equipped with air con ditioning the control panel has a button for engaging the air conditioning compressor This button is marked with a snowflake symbol When the A C is engaged the green LED light in the button is on W38001470
119. eed to reduce pedal effort Failure to do so may result in increased stopping distances Do Not Overload This vehicle has been designed and assem bled for a maximum gross vehicle weight rating GVWR and a maximum front and rear axle weights rating FAWR and RAWR The actual rating for this vehicle can be found on the label attached to the door frame on the driver s side If any of these three ratings is exceeded and over loading occurs instability poor handling failure of parts and accelerated wear can occur N DANGER Under no circumstances should the pub lished GVWR FAWR and or RAWR be exceeded Failure to observe these pre cautions can lead to the loss of vehicle control resulting in a crash causing seri ous personal injury or death N DANGER Do not exceed the load rating of the tires or the vehicle weight ratings Over loading may result in tire failure causing loss of vehicle control leading to an ac cident resulting in severe personal injury or death Operating Before driving this vehicle locate the in struments and controls and become thoroughly familiar with their operation After starting and when driving always check to make sure that the instrument readings are normal General Information W0001210 5 6 General Information Reporting Safety Defects USA The National Highway Traffic Safety Ad ministration NHTSA and Volvo Trucks North America Inc should be informe
120. eheater 00 T3008841 Instruments and Controls 79 2 AINFO Telltale The yellow AINFO telltale lights up to in A dicate a control system or component INFO malfunction In some cases the engine power may be derated see page 120 When the telltale comes on stop at the first safe place where the problem can be checked T3008860 When ignition is switched on the telltale goes out unless a defect is detected NOTE On vehicles equipped with a Volvo engine the telltale is on for 3 to 5 seconds after the ignition key switch is turned on See page 119 for a listing on related mes sages that trigger this telltale 80 Instruments and Controls 3 ASTOP Telltale DANGER Failure to take necessary action when the ASTOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur The AASTOP telltale lights up red to alert the operator that a severe problem has been AN STOP detected and in some cases a preventive ac tion may be taken by the engine electronics T3008861 to protect the engine For example if oil pressure or coolant level drops too low the engine will be forced to low idle and when the vehicle speed is zero the engine shuts down Another example is with excessive coolant temperature the engine will gradu ally reduce power output to 50 This telltale always activates the
121. el is used for distributing loads more favorably be tween the front and rear axles to comply with varying state and provincial laws See page 333 for correct operation Depress the latch and press in the bottom part of the switch to release the slider locks 112 Instruments and Controls Optional Switch Cluster The optional switch cluster can either be used for additional switches when the other clusters are used up or can be removed to house more radio equipment The opening is a standard DIN radio slot Generic switches are available for auxiliary functions that are installed by the customer These should be located in the optional switch cluster and can be purchased from your local Volvo Truck dealer The optional switch panel can be removed and a radio or a Volvo Road Relay can be installed W3000973 W3002419 W3002420 Instruments and Controls Miscellaneous Switches Horn Switches Electric and air horns are standard equip ment They are both operated from the steering wheel The air horn button 1 is located in the middle of the steering wheel If the vehicle is equipped with an airbag SRS the airbag module can be pressed down anywhere around the edge to engage the air horn There are two buttons for the electric city horn 2 located on the steering wheel spokes Instrument Light Dimmer Switch The switch is a rheostat that controls the instrument light Instrument light is activated by the
122. el pad airbag module e No objects accessory equipment or stickers may be placed on attached to or installed near the SRS cover in the center of the steering wheel 65 66 Additional Safety Features General Information When is the airbag deployed The airbag is only deployed during a head on collision where the vehicle hits a fixed or heavy object with sufficient force The SRS system registers both the force of the collision and the internal forces caused by the collision The control unit determines if the collision is sufficiently violent for the airbag to be deployed NOTE The SRS system is only activated once in a collision If the airbag has de ployed the following is recommended e Have the vehicle towed to a Volvo Truck dealer Even if the vehicle can be driven after a collision it is not recommended to drive the truck with the airbag deployed e Have an authorized Volvo Truck dealer change the components in the SRS system e Only use original Volvo parts when re placing the SRS system components airbag safety belt etc When is the airbag not deployed Not all frontal collisions activate the SRS system In a collision with a soft object a snow drift or bush for example or a hard or fixed object at low speed there is no need for the SRS system to be activated The airbag is usually not inflated in re sponse to side on collisions impacts from the rear or if the vehicle overturns The ex ten
123. em Diagnostic see page 137 Data Log Mode see page 152 Password Input see page 158 Driving Mode Menus GAUGE see page 159 FUEL ECONOMY option see page 163 TIME DIST see page 165 FAULTS see page 170 Graphic Display Telltales wo N SmArANI An RA Graphic Display 117 Voltmeter page 162 Engine oil temperature page 159 Transmission oil temperature page 125 Preheating active page 78 Acknowledged warning page 130 Alarm clock on page 167 PTO engaged page 101 Cruise control engaged page 265 Airbag SRS page 63 10 11 12 13 14 15 16 17 W3003534 Coolant level page 126 Washer fluid level page 120 Engine airfilter clogged page 121 Too cold for engine brake page 289 Overheating instrument cluster page 120 Engine preheat fault page 249 Engine oil pressure page 76 Coolant temperature page 75 118 Graphic Display Information and Stop Messages The information and stop messages work together with the AINFO or ASTOP tell tales below the Graphic Display If the engine is running the buzzer will sound at any time the ASTOP telltale comes on Information Telltale NOTE When the yellow AAINFO telltale lights up the indicated fault should be INFO checked at the next stop T3008860 See page 119 for a listing of other telltales that are linked to the AINFO telltale Stop Telltale N DANGER Failure to take necessary
124. engage the locks as soon as possible When the differential locks are disengaged the couplings may be under tension Disen gage the locks by returning the switch to the OFF position Help with the disengage ment by briefly letting up on the accelerator to relieve the torque on the couplings The telltales for the differential locks are in the instrument cluster See page 86 for more information on the telltales W3001991 Xe FE W3000904 Axles and Wheels 313 Wheels General Due to the size equipment needed and the procedures used to change wheels this should be done through the Volvo Truck dealer By having an expert technician per form this procedure personal injury and property damage may be avoided NOTE When replacing the wheel equip ment or tires use the same size wheels or tires as originally manufactured Changing the tire or wheel size will affect brake per formance If changing tire size ABS and speedometer must be recalibrated Check Tightening Wheel Nuts 1 N DANGER Oo of 6 Failure to properly torque tighten the 2 wheel nuts can result in the breakage of O4 wheel studs and the subsequent loss of O wheels Loss of vehicle control and seri O 9 ous personal injury or death could occur 2 ETET Check tighten all wheel nuts after the first 8 and 10 stud wheelnut tightening 50 to 100 miles 80 to 160 km and the sequence first 50 to 100 miles 80 to 160 km after each tire service T
125. engine com ponents increase fuel consumption The list below gives some typical components that can influence fuel consumption e Blocked on the outside charge air cooler radiator package Faulty thermostats Blocked fuel filter Blocked air intake filter Faulty injectors Dirty turbo charger Air in fuel system Faulty fuel supply pump Faulty fuel relief valve Faulty fan thermostat clutch External Environment Under unfavorable conditions the external environment can have a negative effect on fuel consumption This can be broken down into two main groups weather and wind and the nature of the roads Rain snow icy conditions and headwinds have a large neg ative impact on fuel economy as do hilly roads and uneven road surfaces Headwinds Headwinds have a large negative impact on fuel consumption With tailwinds fuel sav ing is only marginal Air Temperature Low ambient temperature contributes to in creased fuel consumption Rain Snow and Road Surface A wet road surface increases rolling resis tance and thereby fuel consumption Slush will increase consumption even more In certain cases the surface structure of the road can also have a negative effect on fuel consumption Gradients A hilly road with many bends demands a higher output from the engine The differ ence between flat straight roads and hilly winding roads can amount to as much as a 50 percent increase in fuel consumption When c
126. ent and can cause serious per sonal injury or death Brakes 285 Antilock Braking System ABS The vehicle has a standard brake system equipped with an electronic speed monitor ing and control system Antilock Braking System ABS ABS monitors wheel speed continuously but is not involved in control ling the wheel speed unless there is an emergency In normal braking applications the standard air brake system is in effect For proper ABS operation do not change tire sizes The size of the tires installed during production are pro grammed into the electronic control unit Installing different sized tires could re sult in a reduced brake force leading to longer stopping distances or accidents There is a sensor installed in each wheel on a monitored axle The sensors transmit in formation to the electronic control unit ECU The ECU interprets the signals and calculates wheel speed wheel retardation and a vehicle reference speed If the calcu lations indicate a wheel lock up situation a signal is sent from the ECU to the appropri ate ABS modulator valve to reduce braking pressure During emergency braking the modulator valve alternately reduces in creases or maintains air pressure in the brake chamber to prevent wheel lock up 286 Brakes During emergency or reduced traction stops fully depress the foot brake pedal un til the vehicle comes to a safe stop DO NOT PUMP the brake pedal With the brake ped
127. ent by Volvo Trucks North America Inc on vehicles which were built to conform to Environ mental Protection Agency and California Air Resources Board regulations IMPORTANT This may not include expendable maintenance items Emission related parts requiring scheduled maintenance are warranted until their first scheduled replacement point I Fuel Injection System II Air Induction System A Intake Manifold B Turbocharge System C Charge Air Cooler Intercooler Ill Exhaust Manifold IV Miscellaneous Items Used in Above Systems A Hose clamps fittings and tubing B Pulleys belts and idlers C Vacuum temperature and time sensitive valves and switches D Mounting hardware sealing gaskets and PVC if applicable THIS CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT IN NO WAY REPLACES MODIFIES ALTERS OR SUPERSEDES THE TRUCK WARRANTY CER TIFICATE ITS TERMS AND CONDITIONS AND ITS LIMITATIONS AND EXCLUSIONS BE CERTAIN YOU READ AND UNDERSTAND ALL WARRANTIES WHICH ACCOMPANIED YOUR VEHICLE NOTE Warranty coverage is subject to change without notice Contact your Volvo Truck dealer for the current warranty statement Noise Emissions Volvo Trucks North America Inc warrants to the first person who purchases this vehi cle for purposes other than resale and to each subsequent purchaser that this vehicle as manufactured by Volvo Trucks North America Inc was designed built and equipped to conform at the time it le
128. entation VN from 3 99 and VHD see page 341 for order information In order to control a specific function it is important to know which menu you are working in When a function is described in this section the information contains the menu name For example PMENU Set Up Mode Language Graphic Display 115 Graphic Display Controls DANGER If the vehicle is in motion use the dis ez play controls carefully Do not lose road concentration Be familiar with operation of the controls Shifting concentration to operating the controls can lead to losing control of the vehicle and may result in serious personal injury or death The controls for the graphic display are lo Esc CB v cated on the windshield wiper lever on the 2 3 4 right hand side of the steering wheel The following commands are available T3008810 1 Esc is used to return to the previous menu and cancel a setting operation 2 Select confirms a highlighted selec tion of a menu or character 3 Up arrow moves the cursor up Used when setting numerical values 4 Down arrow moves the cursor down Used when setting numerical values Selecting a Menu 1 Using the up down buttons the cursor S et up mode is moved to the particular menu which is then highlighted A down ar System diagnostic row in the lower right hand corner shows whether there are any more menus available If this is the case Data log mode you c
129. eper 203 Caging Spring Brakes 339 Canadian Consumer Complaints 6 CB Radio 234 CD Changer 233 Index 343 Change Bulbs In Instrument 95 Cigar Lighter aaa 113 Clock Alarm Sleeper 226 Clock Sleeper i224 2 224 Clutch and Transmission 269 Clutch Operation 269 Cold Weather Operation 252 Collision Warning System VO RAD Te ta a ee ae e 69 Comfort Clip aoaaa 60 Communication and Entertainment231 Coolant Temperature Gauge 75 Cruise Control 265 Cup Holders 229 Curtains ge gee es gg se 230 Daily Maintenance Checks 45 Dash Overview 70 Daytime Running Lights 104 Diff Lock Switch 110 Diff Lock Telltale 86 Differential Locks 311 Display Menu Data Log Mode 152 Display Menu Faults 170 Display Menu Fuel Economy 163 Display Menu Gauge 159 Display Menu Password Input 158 Display Menu Set Up Mode 132 Display Menu System Diagnostic 137 Display Menu Time Distance 165 Door Locks 25 40 4 4 4 4 4 403 20 Door Operation 21 Downhill Operation 263 Drive Axle Oil Temperature Gauge 89 Driving Light Switch 105 E Electric System 120 V 306 Electrical Center 302 Electrical Power Studs 304 344 Index Electrical System 292 Emergency Information 335 Emissions Control Compliance 8 Engine Brake 4 44 44 yak
130. er axle differential lock Never operate the vehicle with the dif ferentials locked any longer than is necessary as this places a great strain on the axles and may cause rapid tire wear The differential lock should be used on icy or slippery surfaces As soon as the slippery surface has been passed the differ ential lock should be disengaged Differential locks must not under any cir cumstances be engaged when in a wheel spin situation Engage the locks ahead of the slippery area If already slip ping stop the wheels engage the locks and then continue If the differential locks are engaged when the wheels are spinning the differential will be damaged and the rear axle drive unit could possibly fail Axles and Wheels 311 312 Axles and Wheels Engaging the differential locks must always be done in the following way see page 110 for switch location 1 Depress the clutch pedal Wait for the drive wheels to stop spinning 2 Engage the differential lock 3 Engage a suitable gear 4 Carefully release the clutch pedal Under normal traction conditions do not engage the differential locks If at all possi ble do not use the differential locks while taking a curve With good traction and the differential locks engaged the vehicle will be understeered and therefore will tend to drive straight in a curve If the locks must be used on good traction surface drive cau tiously and do not exceed 25 mph 40 km h Dis
131. er even if the vehicle is equipped with dual tanks W3003628 Air gauges are directly connected to the air brake system They will indicate the brake application pressure from either the front rear or trailer circuit pressure The gauge will not register air pressure un til the foot brake pedal is depressed or the trailer hand brake is applied W3004302 Air gauges are directly connected to the air suspension system It will indicate the sus pension pressure in the air springs The pressure shown on the gauge is a crude indication of the load on the rear axle s The gauge should not be used for trying to balance the load between the axles W3003633 Instruments and Controls 91 P amp Q Front and Rear Brake System Air Pressures The system air gauges are directly con nected to the front and rear circuit tanks The two gauges should register equal air pressure Air brake system pressure should be between 90 to 135 psi 620 to 930 kPa for normal operation The pointers in the two gauges should register equal air pres sure By observing the gauge pointers the operator can detect a pressure drop if an air leak develops and can readily identify the circuit affected See page 273 for more in formation W3003637 There is a low air warning switch in each gauge If the pressure in a brake circuit air tank drops below approximately 60 psi 420 kPa the red indicator in the lower right corner of the gauge
132. eral Regulations require commercial carriers to provide back of cab access steps grab handles and plates Depending on what option is chosen grab handles are available in many variations In each case make sure to always have three limbs one foot and two hands or two feet and one hand in contact with the vehicle at all times when entering or exiting the area behind the cab Wearing shoes with soles that are dirty W8001363 or wet increases the chance of slipping or falling Be careful when entering the back of cab area with dirty or wet soles Grasp the grab handle to the left with both hands Put the left foot onto the bottom step and pull yourself up Put the right foot on the top step and step onto the deck plate with the left foot Always perform trailer hook ups while standing on the ground Do not climb on top of fuel tanks or frame rails to hook up or disconnect trailer air lines and electrical cord or serious injuries could result from a slip and fall W9000077 26 Vehicle Access Stand on the ground when connecting the air and electrical connections to the trailer Entering Sleeper From Seat Standard Gear Lever When moving from the driver seat to the sleeper section follow this procedure e Make sure the parking brakes are set e Place the gear shift lever in a gear po sition toward the rear of the vehicle e If equipped with an adjustable steering column move the steering wheel
133. erated by a handle on the bottom edge of the dashboard Pull the bottom of the handle out to release hood The hood will be raised about two inches off its resting position and remain there Make sure the hood can be opened fully without hitting anything Stand sideways in front of the hood with feet in line with the vehicle Place feet well apart and grasp the recessed handle in the front part of the hood Transfer the body weight by leaning away from the hood Lift the hood until it is past the balance point Release the hood and let it complete the opening movement unaided Two restraint cylinders will engage during the last part of the opening The cylinders will slow and dampen the hood down to its resting position Make sure that no one is in the way of the hood when closing The hood could injure a person in the way while being lowered To close the hood stand with feet well apart and place the hands along the front edge of the hood Bend the knees and let the leg muscles do the work when lifting Raise the hood up to the halfway point Carefully guide the hood down with enough speed that the hood latches lock the hood in place when it comes to its normal resting position aP Fi l i e a W8000986 W8000982 Manual Hood Opening In the event of a malfunction in the hood opening mechanism the hood latches can be manually operated through an opening in the wheelwell splash shie
134. ere personal injury or death W0001484 N DANGER Never operate the starter without first placing the transmission in neutral or depressing the clutch pedal Failure to follow these instructions may result in the sudden movement of the vehicle re sulting in property damage personal injury or death Engine Start and Operation 245 Before starting the engine perform the engine pre trip inspection and daily maintenance checks in Pre Trip In spection and Daily Maintenance starting on page 32 Make sure the parking brakes are en gaged Place the transmission in neutral or depress the clutch pedal Do not crank the engine for more than 30 seconds at a time wait two minutes after each try to allow the starter to cool Failure to follow these instructions could cause starter damage NOTE Some starters are equipped with an optional thermostat If over cranking occurs the thermostat breaks the electrical circuit to the starter mo tor until the motor has cooled Turn on the ignition with the switch key see page 248 for ignition switch information Some telltales will light up in a routine check that shows that bulbs and systems are OK The AINFO and ASTOP telltales will stay on between 3 to 10 seconds If any of the telltales stay lit that function of the vehicle may not be op i eee erable Do not operate the vehicle until the problem is repaired 246 Engine Start and Operation 5 Turm th
135. ery may freeze e Fuel cloud point is the temperature at which wax crystals become visible which is generally above the pour point of the fuel To keep the fuel fil ter elements from plugging with wax crystals the cloud point should be no higher than the lowest ambient temper ature at which the engine must start To prevent wear and possible damage to the engine when it is cold gradually bring it up to operating temperature before operating at high engine speeds or full load After start ing and before moving the vehicle run the engine at 800 to 1000 r min for 3 to 5 min utes Operate at partial engine load until the coolant temperature reaches 165 F 75 C Engine Block Heater option An electric engine block heater can be in stalled for keeping the coolant hot when the vehicle is parked The heater is mounted through the side of the engine block with the heater coils in the coolant jacket The heater does not interfere with normal oper ation and can be permanently installed The heater runs on 120 V and has an easily accessible plug located under the driver side door The plug will hook up to a nor gt aa mal extension cable 254 Engine Start and Operation Oil Pan Heater option Oil pan heaters aid low temperature starting by improving oil flow to critical parts in the engine This helps prevent engine wear They are similar to block heaters and are wired into the same plug as the engine coolant heater
136. es with a Cummins or Detroit Diesel engine manuals have to be ordered separately from the manufac turer If complete wiring schematics are needed they can be ordered for 150 00 Billing will be done through the nearest Volvo Truck dealer NOTE Prices subject to change without notice Please allow 30 days for delivery Address CSZ Province Postal Code Vehicle Model Phone Fax Model Year Item 1 Item 2 Item 3 Item 4 Item 5 Index A ABS Telltale 2 88 Acknowledge Information and Stop Messages e e ww eee is 130 Additional Safety Features 50 Air Conditioning 174 Air Filters Cab 2 2 187 Air Suspension Gauge 90 Air Suspension Telltale 88 Air Tanks 283 AirbDaS no sas a as 61 Alternator lt lt 4 2 4 293 Antenna Multiplexer 232 Antenas sas on ce eee 231 Antilock Braking System ABS 285 Auxiliary Switches 112 Axles and Wheels 311 Battery Box oe he eG 293 Battery Jump Start 296 Battery Protection System 301 Blind Spots 3 Bobtail Operation 4 Brake Application Gauge 90 Brake System Air Pressure Gauge 91 Brake System Controls 275 Brakes ole greg dbo eke a 272 Brakes General 273 Bunk Access eS 213 Bunk Restraints 53 Bunk Sleeper 24 4 dl a 212 C Brake ge a RG 107 Cab By ek nessa eee ee es ke 24 Cab Interior and Sle
137. ess please wait First No data Last No data Common Fault Codes MID Messages Supported with text MID Description Transmission Instrument Cab Controller Trip Recorder Vehicle Navigation Unit Driver Information Center 172 Off board Diagnostics 1 179 Data Logging Computer 181 Communication Unit Satellite 191 Vehicle Location Unit 231 Communications Unit Satel lite GPS Cellular SRS Description SID 1 Driver Airbag Ign Loop Graphic Display 143 PID Description code 62 Retarder inh status 71 Idle shutdown status 84 Road speed 91 Throttle pedal 100 Engine oil pressure 102 Boost pressure 105 Air inlet temperature 106 Air inlet pressure 108 Barometric pressure 110 Engine coolant temperature 111 Coolant level 127 Transmission oil psi 160 Main shaft speed 161 Input shaft speed 175 Engine oil temperature 177 Transmission oil temperature 190 Engine speed 191 Transm output RPM PSID Proprietary Subsystem ID PSID Code PSID 1 PSID 2 PSID 3 Description Retarder Brake Control Set Switch Idle Validation Switch 2 Idle Validation Switch 3 PSID 4 Retarder Brake Control Switch h 44 Graphic Display Common Description SID code 233 Controller 2 236 Power contact device 237 Start enable solenoid 242 CC resume switch 243 CC set switch 244 CC enable s
138. essure is then delivered to the wheel brake chambers as required by the amount of pressure exerted on the foot brake pedal The brake chamber force then applies the wheel brakes Brakes 275 W5000920 276 Brakes From the operator s viewpoint operating the foot brake valve of a vehicle equipped with air brakes differs very little from the operation of a conventionally braked vehi cle Because the operation of the brake pedal requires scarcely more effort than de pressing the average throttle pedal air brakes are naturally much easier to control If the driver gives full attention to the fol lowing suggestions a little experience will make him her thoroughly familiar with the air controlled braking of this vehicle N DANGER Failure to observe these precautions can result in loss of brakes loss of vehicle control vehicle accident and serious personal injury or death 1 The best possible stop will be made when the first brake application is as firm as the speed and road condition permit Then ease off as the speed is reduced Never apply the brakes lightly at first and increase the pres sure as the speed diminishes 2 Do not fan the brake pedal Fanning gives poor brake performance and wastes air 3 The air brake is designed so that when the brake pedal is fully depressed an emergency application results This application should be made only in an emergency situation Brakes In making a stop or a
139. f the fifth wheel plate e Make sure the mounting of the fifth wheel to the frame is tight and in good condition e If using a sliding fifth wheel make sure the slide locking plungers are in a locked position The following instructions are for preparing the fifth wheel for coupling to a trailer Rotate the safety latch toward the rear of the fifth wheel W9000180 Using a slight upward motion pull the op LEE FZ e erating rod out until the operating rod SS aC shoulder is outside the fifth wheel operating NY 7 slot BS Sg meer ee a oe Ww9000202 322 Fifth Wheel Instructions When the shoulder of the operating rod is outside of the operating slot raise the oper ating rod handle to its maximum upward position w9000242 Release the operating rod The upper shoul der of the operating rod should now be in contact with the plate casting above the op erating slot The fifth wheel is now in the lockset position and a trailer can be coupled W9000274 Fifth Wheel Instructions 323 Trailer Coupling Procedures This procedure covers vehicles with and without air suspension N DANGER Failure to properly couple the tractor and trailer can result in trailer separation causing death and property damage W8001449 Using the following procedures inspect the equipment before coupling to a trailer Make sure the fifth wheel is properly lub
140. ff To change the language permanently a pass word is required see page 116 1 To set the desired language press SE LECT when you are in the menu Set up mode Language 2 On the graphic display up to three dif ferent languages will now be shown Select the desired language by moving the cursor to the particular row Con firm the choice with SELECT Cancel setting Press Esc in order to cancel the setting English Spanish French Miles F USgal or km C MENU Set up mode Mi F USgal or km C NOTE If Miles and Fahrenheit are chosen the fuel consumption is shown in US gal lons If kilometers and Celsius are chosen the consumption is shown in liters 1 Select the menu Set up mode Mi F USgal or km C and the fol lowing diagram is shown on the graphic display with the particular setting highlighted The up down buttons move the cursor between the alternatives 2 Confirm the choice with SELECT 3 When km and C are chosen the following is shown on the graphic dis play with the particular setting highlighted The up down buttons move the cursor between the alternatives 4 Confirm the choice with SELECT Cancel setting Press Esc in order to cancel the setting Graphic Display 133 km and C Mi USgal and F Select fuel data unit km l 1 100 km 134 Graphic Display Clock format MENU Set up mode Clock format 1 Select the menu Set up mode Cloc
141. flow W8002038 Panel in VN 420 610 and 660 W8002014 Panel in VN 770 Heating and Air Conditioning 185 Cab Ventilation In sleeper versions except the VN 770 there is a fresh air vent located on each cab side wall It opens to two positions so the air flow can be regulated The vent also opens toward the front or to ward the rear This can be used for forcing air into the cab open toward the front or for venting air out of the cab open toward the rear The vent should not be used during rain while washing the vehicle or other cir cumstances where water may enter the cab while the vent is open To prevent leaks make sure the handle rollers are on the top center part of the cams The VN 770 is equipped with 4 hinged side windows in the sleeper area The VN 660 has only the upper windows Do not force the window crank mechanism in the fully open position The mechanism can be damaged if you try to open the window be yond the stop position Make sure windows are closed before w8001473 washing the cab Water can enter the cab through the window opening 186 Heating and Air Conditioning Ventilation Guidelines If at any time there is any doubt that ex haust fumes are entering the cab have the cause of the fumes determined and cor rected as soon as possible If the vehicle must be driven under these conditions drive only with all windows open Protect against carbon monoxide entry into
142. ft the control of Volvo Trucks North America Inc with all applicable U S EPA Noise Control Regulations This warranty covers this vehicle as de signed built and equipped by Volvo Trucks North America Inc and is not limited to any particular part component or system of the vehicle manufactured by Volvo Trucks North America Inc Defects in design as sembly or in any part component or system of the vehicle as manufactured by Volvo Trucks North America Inc which at the time it left the control of Volvo Trucks North America Inc caused noise emissions to exceed Federal standards are covered by this warranty for the life of the vehicle General Information 13 14 General Information Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Air Intake System Removing or rendering inoperative the air cleaner or intake piping Engine Cooling Fan Removing or rendering in
143. g a pre trip inspection prepares for the end of work re port Starting on the next page are suggested guidelines to be used in performing truck tractor and trailer pre trip inspections De pending on the application of the vehicle being used these guidelines should be modified to include other necessary inspec tion points For example steps and grab handles should be checked daily on refuse trucks because the operator is getting in and out of the cab more frequently If any component or system does not pass this inspection it must be corrected before operating the vehicle Whenever equipment requires adjustment replacement repair or lubrication refer to the Service Manuals or contact a Volvo Truck dealer for the correct procedures specifications and intervals Take your time going through the pre trip inspection Remember that a careful pre trip inspection saves time by eliminating un scheduled stops for correcting a faulty item The following information has been provided by the American Trucking Associ ation as developed by the D O T Office of Motor Carriers BMCS Pre Trip Inspection and Daily Maintenance Pre Trip Inspection Quick List n same oo gt N aio 33 W0001230 Inspect the vehicle in a circular manner as shown in the illustration Numbers between parentheses in the list re fer to pages in this manual where component function and necessary inspection is explained in greater detail Ste
144. g signal sounds The alarm is switched off after 60 seconds or when the up down Esc or SELECT control button is pressed Activate alarm clock without changing the time of the alarm call 1 The cursor is moved with the up down Beo ON ALARM 08 30 AM T3008833 2 SELECT activates the alarm clock and CLOCK O8 00 AM the symbol is shown on the graphic display ai ON OFF SET Cancel setting Press Esc in order to cancel the setting De activate the alarm clock 1 The cursor is moved with the up down 4 E aoe ALARM 08 30 AM CLOCK 08 00 AM 2 SELECT switches off the alarm clock and the symbol disappears from the ON OFF SET graphic display Cancel setting Press Esc in order to cancel the setting Tripmeter MENU TIME DIST TRIPMETER On the display in the menu TRIPMETER the distance driven for Leg 1 and Leg 2 are shown Reset tripmeter 1 Press SELECT in the menu TRIPME TER 2 A new text message with a question about the resetting of the tripmeter is shown The up down buttons move the cursor between Leg 1 and Leg 2 Con firm the choice with SELECT or press Esc in order to cancel the resetting Average speed MENU TIME DIST AVERAGE SPEED The average speed is calculated using the distance driven divided by the time the en gine has been running since the last resetting Reset average speed 1 Press SELECT when the menu AV ERAGE SPEED is shown 2 A new text message with a question about t
145. g water drain off turn counter clockwise and the spring will lift the plug and open the drain Cab Interior and Sleeper Fresh Water Tank Water is drawn from the fresh water tank 1 located beside the waste water tank 2 in the left hand side luggage compartment Refill fresh water tank with potable drink ing water only Tank volume is 9 gallons 34 liters On top of the tank is a hose 3 that serves as a filler and a vent tube In the bottom of the tank is a drain valve 4 with a hose attached for draining the tank to the outside It is not recommended to let water remain unused in the tank for over 2 months Clean and refill as necessary A N CAUTION USE POTABLE DRINKING WATER ONLY Verify with the supplier of any water prior to filling the fresh water tank that it is potable to avoid contamination of the tank In the event that non potable or contaminated water enters the fresh water tank it should be drained and the tank should be cleaned out with a good commercial cleaner disinfectant The tank should also be tested for purity prior to being used for drinking It may be necessary to replace the tank if it cannot be cleaned properly A N CAUTION Fresh water and waste water tanks must be drained if the vehicle is not being used and the outside temperature is be low freezing Also drain the hose from the pump to the faucet Failure to drain the system may result in component damage due to water forming ice
146. ght Inter axle diff lock good road conditions If a differential lock telltale is activated in the instrument clus ter do not make turns until the telltale has y gone out See page 311 for information on feo a how to properly engage and drive with dif amp ferential locks engaged Vv 4 W3000904 Telltales Instruments and Controls 111 Suspension Level A N CAUTION The vehicle must never be driven with the air springs deflated Damage to air suspension parts will occur if springs are not inflated properly Tractors with rear air suspension have a dodi control for deflating the air springs Use this when uncoupling from trailers See page 329 for correct operation when uncoupling The switch has a safety latch to prevent ac cidental engagement Depress the latch and press in the bottom part of the switch to deflate the air springs A telltale in the in strument cluster will light up when the switch is in the on position Sliding Fifth Wheel N DANGER The release must never be operated while the vehicle is operating on the road Fifth wheel position adjustment must only be done when stationary Damage to the fifth wheel trailer king pin and slider may occur if not operated properly and may lead to an accident causing serious personal injury or death W3001346 Tractors with a sliding fifth wheel mount ing have an air operated release as standard equipment The sliding fifth whe
147. ging 308 Headlight Switch 104 Heated Mirror Switch 109 Heater Parking 189 Heating and Air Conditioning 174 Hi Beam Telltale 87 Hi Lo Beam Switch 97 High Altitude Operation 264 Hood Opening 30 HOS 3 ee thot oud eo G 113 Idle Adjustment 261 Idle Shutdown 262 Jang en aa a a 260 Ignition Switch 248 Inflating Tires 314 INFO Telltale 40s 4s ae Gs esa 79 Info Telltale 4 ea eR 3 119 Information and Stop Messages 118 Inspecting Safety Belts 55 Instrument Cluster Left Overview 74 Instrument Light Dimmer 113 Instruments and Controls 70 Instruments Overview 70 Interior lights 203 Jake Brake 40 a ante aa 107 Jump Start ee a gk tg iy 296 Jump Starting Engine 297 Lights Daytime Running 104 Luggage Compartment 29 N P Main Instrument Overview Marker Interrupt Switch Master Warning Telltale Mirror Defrost Telltale National Comfort Seat National Standard Seat No Charge Telltale Noise Emissions Odometer Oil Pressure Gauge Overload Owner Information General Owner s Information Package Parking Brake Parking Brake Telltale Parking Heater Parking Spring Brake Power Outlets 12 V Power Outlets 120 V Power Steering Power Steering General Power Studs odio Beaders Pre Trip Inspect
148. gned to maintain a constant temperature in the cab which is set by the temperature control As the sys tem does not make automatic changes of fan speed a selection of higher or lower fan speed to allow for more or less air flow may have to be made to achieve the correct temperature 176 Heating and Air Conditioning Air Distribution Control The air distribution control is used to direct the air flow to either the dash vents floor vents or defroster vents The lever has de tentes in the outer and middle positions so that it can be set without looking at the panel W8001467 The air flow for the three major settings are described below Any setting outside of the detented positions will be a mix of the air flows that depends on how far from the de tented position the lever is gt With the control in the leftmost d position all air is directed out through the vents in the dash e With the control in the middle Ww position most air is directed out through the floor vents and the cab door window vents A small flow is directed out through the vents in the dash This mix is approximately 80 20 With the control in the right iy most position most air is directed out through the front dash vents to the windshield and cab door windows A small flow is directed out through the vents in the dash This mix is approx imately 70 30 NOTE When the air vents on the dash are open some air
149. good working condition Any defects should be re ported and repaired before using the grab handles and steps Do not step on the curved surface of the fuel tanks They may be slippery from snow mud ice water spilled fuel or other slippery substances If a step is mounted to the top of the battery box be certain that the battery 10 11 12 13 14 15 16 Vehicle Access 23 box cover is properly fastened before stepping Do not jump from the cab or from the steps to the ground Always face the cab when entering or exiting Do not hold anything in your hands when entering or exiting the cab or the area behind the cab Log books cups clipboards jackets luggage and the like can be placed on the cab floor or rear deck plate before entering or exit ing Be sure to disconnect the safety belt before exiting the cab Be sure that the safety belt is fully re tracted and out of the way prior to entering or exiting the cab Do not put your foot on any surface that does not have slip resistant self cleaning material If there is no step material the surface may be slippery and you could fall Before entering or exiting be certain that the soles of your shoes boots are free from grease mud or any other substance which could make them slippery Always put the foot flat on the top of the step Do not place your foot on the side or edge of the step BE SURE TO FOLLOW ALL OF THESE INSTRUCTIONS
150. he sleeper vent layout of the VN 770 For the best results when using the air con ditioning direct the air flow upward in the sleeper area W8002033 184 Heating and Air Conditioning Sleeper Climate Unit With ATC The ATC panel is located on the left side behind the driver seat and contains a tem perature control fan speed control and other controls To use the heater with the engine running and the air conditioning button on the main control panel in the off position turn the fan speed control 1 and the temperature control 2 to the positions that give the de sired temperature output To use the air conditioning the engine must be running Press in either the manual air conditioning button with manual A C the fan switch must be at least on speed 1 or the ATC button on the main control panel in the dash The ATC control unit for the sleeper climate system will keep the temperature output to where the tempera ture control was set However the fan speed may also have to be adjusted in creasing or decreasing air flow to achieve correct cab temperature The air conditioning works together with the heater to give the desired temperature output Use the temperature control 2 to adjust the output air temperature by turning the control counterclockwise toward the blue field for colder air and clockwise to ward the red field for less cold air Also use the fan speed control 1 to alter the amount of air
151. he passenger side there is the option of a stationary seat The base of the seat is a storage box that is accessed by lifting the seat cushion up W8001386 No Passenger Seat option DANGER Using a temporary passenger seating without the benefit of proper seat mounting and safety belt can in the event of a loss of control of the vehicle cause serious personal injury or death In vehicles with no passenger seat installed Do not let a passenger ride on temporary seating This is against the law and can be very dangerous Cab Interior and Sleeper 203 Interior Reading Lights Front Of Cab The cab is equipped with separate and a combined interior and reading lights in var ious locations in the cab The front seat overhead lights can be turned on at any time using the switch in the fixture By turning the switch the other way the light will be activated by the cab door switches ey Any time the door is opened the light comes on When the switch is in the mid dle position the light does not light up even when the door is opened ad W3003981 a a L i f E r W3000974 There is also a light on the inner front face of the door that can be activated by the switch or be set to come on when the door opens The lens is red so the light is used to alert oncoming traffic from the rear that the door is open It is also used during night driving to light up the floor area and steps without di
152. he resetting of the average speed is shown Confirm the choice with SELECT or press Esc in order to cancel the resetting Graphic Display 169 TRIP 1 43 6 mi 2 507 3 mi RESET 1 2 PRESS SELECT FOR 1S AVERAGE SPEED 55 4 mph RESET PRESS SELECT FOR 1S 170 Graphic Display Main Menu FAULTS General When a fault occurs a fault message is shown on the graphic display There are two types of fault messages 1 Information messages 2 Stop messages The stop message is always more urgent than information messages Any information and stop messages as well as the associated symbols are shown auto matically on the graphic display when driving A summary of these symbols is shown in the illustration under page 172 Under the display there are two lamps a yellow AAINFO telltale and a red ASTOP telltale that attract the driver s attention when necessary When the red stop tell tale lights up and the engine is running a warning signal is also activated Several messages may be active at the same time When a new message is activated the new one is shown instead of the old one A down arrow in the graphic display s right hand corner means that more mes Sages are active Information message The yellow telltale lights up when an ab normal state or a risk situation is indicated In addition to the telltale a symbol or text is shown on the graphic display at the same
153. his applies to both sin gle and dual wheels in connection with normal service but should be performed at least every six months This check tightening is particularly impor tant when rims or brake drums are newly painted Paint can flake off from these sur faces causing the nuts to lose their grip and the wheel to loosen 314 Axles and Wheels Inflating Tires Always check inflation pressures when the tires are cool using an accurate tire pres sure gauge Check the pressures at regular intervals Never bleed the air from hot tires In creased tire pressure measured in a hot tire is normal Lower than recommended pressures may cause side wall flexing re W7000437 sulting in increased tire heat This may cause premature tire failure 3 mm 1 5 mm AN DANGER 1 8in 1 16 in Tires and wheels must be serviced only by a qualified technician Do not attempt to perform this work yourself Inflated tires on wheels contain compressed air and if suddenly released do so with an explosive force Serious personal injury or death can occur For specific information and warranty on rims and tires contact the tire manufac turer s distributor Check tires for abnormal wear Also check the tread depth STEER TIRE DRIVE TIRE W7000773 Axles and Wheels 315 Wheel Bearing Adjustment For reliable operation and adequate service life the wheel bearings must be properly adjusted and checked during the serv
154. hoosing your route avoid hills rough roads and frequent stops See table with fuel consumption for the D12C 465 USO00 with gross combined weight of 80 000 1b 40 t or 36 3 metric ton Fuel Economy Driving 241 Maximum Fuel Acceleration Consumption 0 45 mph 0 45 quarts 70 Km h 0 5 liters 0 65 mph 1 0 quarts 105 Km h 1 1 liters 242 Fuel Economy Driving Driving Habits The way in which a vehicle is being driven is the one factor which has the greatest in fluence on fuel consumption Correct driving saves fuel and reduces vehicle wear To achieve optimal running economy the driver should always remember to e Start the engine correctly especially important in winter season e Maintain an even and correct speed e Keep the engine at its optimum speed range e Use the correct uphill and downhill driving technique Starting the Engine Start the engine according to the instruc tions in the Operator s Manual of the engine manufacturer for a Volvo engine see page 245 A proper start especially during the cold season saves fuel and re duces engine wear Sluggish lube oil in the engine makes cold starting more difficult Therefore it is im portant to always use engine oil with the correct viscosity For the sake of the over all fuel economy it is also important to have the right viscosity of transmission and rear axle oils Fuel Economy Driving Avoid High Engine Speeds High engine s
155. ice pe riod Loose wheel bearings could cause premature tire wear and possibly affect ve hicle handling See your Volvo Truck dealer for proper servicing Watch carefully for oil leaks and listen for unusual noises These are indications of worn bearings bad seals or misadjusted ree bearings These are problems which must be corrected as soon as possible N DANGER Failure to keep wheel bearings properly adjusted may result in accelerated tire wear poor handling and wheel separa tion from the vehicle Failure to properly maintain bearings can ultimately result in loss of wheel and vehicle control and cause serious personal injury or death 316 Fifth Wheel Instructions Fifth Wheel General Information The standard fifth wheel is manufactured by ASF Other fifth wheels available as op AX DANGER tions are Holland and Fontaine Always have all fifth wheel maintenance Things to think about with trailer hook up and repairs done by a qualified techni Ses cian An incorrect repair can cause the e Check the load distribution between trailer to separate from the tractor caus axles ing an accident with serious personal inj death e Always chock the trailer wheels ce hie a i e Grease the plate No grease on the plate will produce heavy steering e Verify visually that coupling has oc curred e Verify visually that plungers have locked on slider e Check for slack between the 5th wheel and the trailer ki
156. icle is defective the part will be repaired or replaced by Volvo Trucks North America Inc This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner you are responsible for the performance of the required maintenance listed in your owner s manual Volvo Trucks North America Inc recommends that you re tain all receipts covering maintenance on your truck but Volvo Trucks North America Inc cannot deny warranty solely for the lack of receipts or for your failure to ensure the per formance of all scheduled maintenance You are responsible for presenting your vehicle to a Volvo Trucks North America Inc dealer as soon as a problem exists The warranty repairs should be completed in a reason able amount of time not to exceed 30 days As the vehicle owner you should also be aware that Volvo Trucks North America Inc may deny you warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifications If you have any questions regarding your warranty rights and responsibilities you should contact Volvo Trucks North America Inc Warranty Administration 336 393 2000 or the California Air Resources Board at 9480 Telstar Avenue El Monte CA 91731 10 General Information EMISSION CONTROL SYSTEM WARRANTY Volvo Trucks North America Inc WARRANTS TO THE ORIGINAL OWNER AND EACH SUBSEQUENT OWNER OF A NEW TRUCK POWERED BY A
157. in a blind spot area with an optional side mounted radar The Collision Warning System warns the driver of potentially dan gerous situations by activating visual and audible alerts N DANGER The Eaton VORAD Collision Warning System is intended solely as an aid for an alert and conscientious professional driver It is not to be used or relied upon to operate the vehicle Use this system together with rear view mirrors and other instrumentation to maintain safe operation of the vehicle Operate a VO RAD equipped vehicle in the same safe manner as if VORAD was not installed The Eaton VORAD Collision Warning System is not a substitute for safe driv ing procedures nor will it compensate for any driver impairment such as drugs alcohol or fatigue The Eaton VORAD Collision Warning System may provide little or no warning for some hazards like alerts for pedes trians animals oncoming vehicles and cross traffic SmartCruise will not react to stationary objects and it does not have the capability to stop the vehicle Failure to follow these instructions may lead to a crash resulting in severe per sonal injury or death If your vehicle is equipped with the Eaton VORAD Collision Warning System read the manufacturer s Driver Reference Man ual before taking the vehicle on the road 70 Instruments and Controls Dash Overview SmAANIA MN B amp B WN Air Vents page 182 Diagnostic Test Connection Left Switch Cluste
158. ine is equipped with a preheater Introduction of ether or other combustible material in the intake manifold could cause a fire or explosion resulting in severe property damage se vere personal injury or death NOTE Volvo engines have a unique cold start feature Depending on the ambient temperature the engine cranks two to four turns without injecting fuel This provides cleaner combustion at start up and pro motes longer engine life To avoid excessive exhaust smoke when starting a cold engine the intake air should be warmed up by using the preheater Turn the ignition key to the preheat posi tion and hold momentarily to engage the preheater It remains engaged and will light the preheater telltale between O and 50 sec A onds depending on the engine coolant temperature 249 250 Engine Start and Operation Coolant Preheater Temperature Engagement Time seconds Above 120 F 50 C 0 Above 50 F 10 C 0 Between 4 F 15 C 25 2 to50 2 and 50 F 10 C Below 4 F 15 C 50 When the engine has started the preheater may be re engaged to assist in faster engine warm up To re engage turn the key to the preheat position and the preheater will en gage The starter will not engage as the start position is locked out Engines Without Preheater Engines not equipped may depending on coolant temperature take longer to start If this should happen do not release the igni t
159. ing the bar is not shown and the fuel consumption is shown in gal hour NOTE If km and C have been selected the consumption is shown in liters In the example above L 100 km will then be shown instead of mpg 164 Graphic Display Reset fuel economy 1 Press SELECT in the menu AVG INST 2 A new text message in the form of a question is shown RESET FUEL DATA Press SELECT to reset When the leg s fuel consumption is reset the average fuel consumption will also be reset Leg Fuel MENU FUEL ECONOMY LEG FUEL Press the up down buttons in the menu AVG INST to reach the menu LEG FUEL The following is shown in the menu LEG FUEL on the display e The Leg fuel consumption amount of fuel used since the last resetting e Empty XXX mi where XXX is the calculated range using the present in stantaneous consumption NOTE If km and C have been selected the consumption is shown in liters In the example below L will then be shown in stead of USgal NOTE Since the calculated range is based on the instantaneous consumption the correct value is first shown shortly after Start RESET FUEL DATA PRESS SELECT FOR 1S LEG FUEL XXX EMPTY XXX mi Main Menu Time Distance Menu TIME DIST has 4 sub menus e CLOCK e ALARM CLOCK e TRIPMETER e AVERAGE SPEED NOTE Menu TIME DIST is available even when the ignition key is in the off po sition It is activated by keeping one of the co
160. ion Service 341 Volvo Comfort Seat 199 Volvo Standard Seat 198 VORAD Collision Warning System 69 Warning temperature transmission ON ce dtl pee Ge a ce oe me oe 129 Welding On Frame 7 Welding Precautions 7 Wheel Bearings 315 Wheel Nuts 5 ae ee ao ie 313 Windows Sleeper VN 660 amp VN PU ek Be ee ele og ad 228 Windshield Washer Capacity 47 Windshield Washers 98 Winterfront 255 Wipers a ee ae ae 98 Vehicle Identification Number Chassis Number Truck Model amp Serial Engine Model amp Serial Transmission Model amp Serial Rear Axle Model amp Serial Your Truck Was Delivered By 1 800 52 VOLVO Volvo Action Service VAS Support Center If you need breakdown assistance contact the VAS Support Center for towing or repair VAS is available 24 hours per day 7 days per week at 1 800 528 6586 A Volvo Customer Support Specialist will answer your questions or arrange for the assistance you need VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 6490 Vipond Drive Mississauga Ontario LST 1W8 http www volvotrucks volvo com PV776 TSP20 154796 4 000 4 2001 Volvo Trucks North America Inc 2001
161. ion and Daily Maintenance lt 3 lt 3 iq lt 2 a2 4 Preheater Telltale Pressure Gauge Oil Pressure Gauge Turbo Boost PTO Speed Adjustment Pyrometer Gauge R digso aor ee a aa ae aa ae Raise Hood Rear Axle Serial Number Loca tions Volvo Road Relay Roadside Assistance S Safety Belt Replacement Index 345 Safety Belt Telltale 87 Safety Belts ae gf Ge ES 50 Safety Defects Reporting 6 Safety Equipment 68 Safety Guidelines Electrical Sys teenie teen Gee ee eee Boke ad 292 Safety Guidelines Fifth Wheel 318 Safety Information Brakes 272 Seat National 196 Seat Stationary 202 Seat Volvo 2 2 2 199 SCAS 5 te we ee ene E a S a a 195 Selling Vehicle 2 4 gd ee 3 1 Service Assistance 341 Service Information 341 Service Manuals 342 Sink in Sleeper 220 Sleeper Bunk Restraints 53 Sleeper Bunks 212 Sleeper Curtains 230 Sliding 5th Wheel Switch 111 Smoke Detector 224 Speedometer 83 Spring Brake Chambers Caging 339 SRS Airbag 61 Steering Column Adjustable 310 SETE cd ig ok oe eee ee ee ee tg 233 Stop Engine Telltale 80 Stop Telltale 126 Storage Front Overhead 206 Storage VN 610 amp VN 660 207 Storage VN 770 209 Suspension Level Switch 111 Switches Left Cluster 99 Switches Optional
162. ion in the daycab VN 420 VN 610 and VN 660 is 800 Ib 360 kg with driver and passenger included To tal load for the cab suspension in the VN 770 is 1 000 Ib 455 kg with driver and passenger included Overloading the suspension leads to poor ride and low ered driving comfort W8001098 Cab Interior and Sleeper 207 VN 610 and VN 660 Storage The VN 610 sleeper overhead storage comes in two sizes If the sleeper contains an upper bunk only the short cabinets are available Each cabinet has a netting that covers the opening to hold items in place during driving The short compartment load limit is 33 Ib 15 kg The long compartment load limit is 40 lb 18 kg In both VN 610 and VN 660 there are two floor cabinets a clothes hanger cabinet and a drawer cabinet The drawers have latches for holding them in place during driving The top drawer also has a key lock so it can be used to store documents There is also a pull out writing tablet in the top part of the cabinet The drawer cabinet load limits are 9 5 1b 4 3 kg for the top drawer and 14 5 Ib 6 5 kg each for the two lower drawers The drawer cabinet is substituted for a re frigerator when this option is chosen The clothes hanger cabinet does not have a load limit since it is resting on the floor In the VN 660 with an upper bunk there are two overhead storage cabinets The larger opening is covered with netting for holding items in place during
163. ion key until the engine has started while still observing the 30 second maximum cranking time Engine Start and Operation 251 Ether Start N DANGER Do not use ether or similar starting aids a in a Volvo or other engine with a pre heater The Volvo engine is equipped with a preheater Introduction of ether or other combustible material in the intake manifold could cause a fire or explosion resulting in severe property damage se vere personal injury or death DANGER arr Do not breathe the ether fumes Breath ing ether fumes could result in personal injury or death DANGER If using a cold start system make sure to read and follow the manufacturer s in structions regarding its use handling and storage Many starting fluids are sold in capsules or pressure cans and improper usage can be dangerous resulting in ex plosion personal injury or death Ether allows combustion with lower cylin der temperatures A hand held spray can for injecting ether through the engine air intake system will usually provide quick starting to as low as 10 F 23 C Below this tem perature a permanently installed system for injecting a combustible vapor directly into the intake manifold is necessary Only inject ether vapors when the engine is cranking Use it sparingly Excessive ether use can cause piston and ring damage 252 Engine Start and Operation Cold Weather Operation If the engine is in goo
164. ir pres sure is low and the remaining air volume may not be enough for repeated braking The emergency brakes may engage ee causing a wheel lock up loss of vehicle control and become a hazard to follow ing vehicles Bring the vehicle to a controled stop Failure to follow these precautions can result in loss of braking control and serious personal injury or death can occur as a result of a vehicle accident This will light up when either front or rear air brake system pressure drops below 60 psi 410 kPa or lower The buzzer will also sound when the telltale lights up When the pressure goes above 60 psi in both front and rear brake circuits the tell tale will automatically go out Air brake system pressure should be be tween 90 to 135 psi 620 to 930 kPa for normal operation The master warning tell tale comes on and the buzzer sounds when air pressure has dropped to 60 psi or lower If the air pressure is allowed to drop below 30 to 40 psi 200 to 275 kPa in both systems the parking spring brakes will au tomatically engage and stop the vehicle When the master warning telltale comes on and before the parking spring brakes en gage stop the vehicle in a controlled manner at an off road location so as not to be a hazard to other vehicles on the road Refer to page 273 for more information about the brakes Instruments and Controls 85 K Warning Telltales Center Section 1 3 5 7 9 11 Seo A Oelen
165. ir tanks should be drained daily Make sure the drain cocks close properly after draining Empty moisture from air tanks by pulling the drain valve wire The tanks should be checked for condensation fluid even if an automatic drain valve is installed 283 W5001035 W5000601 284 Brakes The 121 Brake Standard This manual refers occasionally to 121 brakes Although some operators believe 121 only applies to vehicles equipped with anti lock devices the 121 standard applies to all vehicles that are capable of on highway operation The 121 requirement also covers alter ations or changes to parts or systems related to the 121 standard once the vehi cle has been placed in service The owner and operator should be aware that it is a vi olation for any repair facility to make any part or component inoperative when it is required for 121 compliance Charging Air To Another Vehicle There are many methods which may be used to charge the air system of another ve hicle Vehicles equipped with the standard two valve system trailer supply and parking brake must use the following pro cedure when using the emergency trailer air line as an auxiliary air source other than to charge the trailer air reservoirs N 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 movem
166. is very helpful when ordering parts for your vehicle Vehicle Order The Vehicle Order is a complete and de tailed record of all data pertaining to the assembly of the vehicle It should be filed in the Owner s office where it will be read ily available for reference Any changes made to the vehicle must become a part of the Vehicle Order and must comply with all applicable Federal Motor Vehicle Safety Standards W0001995 General Information 17 Identification and Certification Labels There are two labels that are located on the rear lower face of the driver side door frame These should be part of the vehicle at all times The VIN is shown on the Vehicle Identifi cation label The VIN includes the vehicle make model series weight class engine model where the vehicle was built and the vehicle serial number This label also shows the truck model designation major component model and serial number cab model and serial number cab and chassis paint colors and color numbers On the upper part of the door frame is the Certification label showing the axle and load ratings for the vehicle as it was built Do not exceed these ratings by overloading NOTE To deter tampering with the origi nal build information the information on j the label will be destroyed if label is woii removed If for any reason a label is dam aged contact your Volvo Truck dealer for a replacement Noise Emission Control A Nois
167. ite background with a black border A warning label directs the operator s attention to unsafe practices which could result in personal injury or severe dam age to the vehicle The warning label is in black type on a gray background with a black border N DANGER A danger label directs the operator s at tention to unsafe practices which could result in serious personal injury or death The caution label is in white type on a black background with a black border Information For the Owner If there are questions on the maintenance and performance of your vehicle please discuss them with your Volvo Truck dealer Your authorized dealer is required to have trained mechanics special tools and spare parts to fully service your vehicle If necessary your dealer will contact the man ufacturer for any assistance In addition to this Operator s Manual there may be additional instruction operator s manuals supplied by component manufac turers These manuals are placed in the Owner s Package and placed in the cab Be sure to read all the manuals thoroughly be fore operating the vehicle Also various safety labels may be placed on components by the component manufac turer Be sure to read and follow these labels to prevent damage to the vehicle personal injury or even death Information in this manual refers to Volvo components and Volvo drivetrain Informa tion concerning non Volvo engines and or drivetrains
168. k AM PM format and the following diagram is shown on the graphic display with the 24h particular setting highlighted The up down buttons move the cursor between the alternatives Confirm the choice with SELECT AM PM is the 12 hour display AM morning and PM evening Cancel setting Press Esc in order to cancel the setting Contrast MENU Set up mode Contrast 1 2 Select the menu Contrast and the fol Adjust contrast lowing diagram is shown on the graphic display The bar shows the particular setting in relation to max min contrast The up arrow increases the contrast The down arrow reduces the contrast Confirm the choice with SELECT Cancel setting Press Esc in order to cancel the setting Backlight MENU Set up mode Backlight NOTE This setting affects the display brightness when the headlights or parking lights are on When the exterior lights are off the brightness on the display is con stant The graphic display brightness is controlled by the dimmer rheostat setting which also controls the other instrument cluster light ing In this menu the display lighting can be altered in relation to the other instru ment cluster lighting 1 Select the menu Backlight and the following diagram is shown on the graphic display The bar shows the particular setting in relation to max min lighting the up arrow button increases the background lighting the down arrow button
169. ke and the compression brake are acti vated For the engine brake to function the following must be in effect W3001324 The switch is ON Vehicle speed over 7 5 mph 12 km h Engine temperature over 110 F 43 C Accelerator and clutch pedals are fully released e Engine speed over 1 100 r min When the cruise control is engaged the en gine brake automatically engages if the selected cruise speed is exceeded by ap proximately 5 mph 8 km h The engine brake is then disengaged when the speed has returned to approximately 3 mph 5 km h above selected cruise speed Too Cold for Engine Brake Volvo Engine Only Position 2 of the engine brake should not be switched on until the engine has become warm over 110 F 45 C If position 2 is selected and the engine is too cold this symbol will be shown however VEB is 73009355 not activated Jake Brake Or C Brake The Jake Brake or C Brake is optional equipment for Cummins and Detroit Diesel engines These engine brakes are similar in operation Three power levels are available by engaging 2 4 or 6 cylinders when brak ing For Cummins M11 only two power levels are available It is operated by two switches in the right hand switch cluster It works together with the exhaust brake to provide two levels of braking power The left switch is the ON OFF switch The desired braking power is selected with the right switch which has three positions LOW MED an
170. kes 273 DANGER N DANGER Do not release the parking brake or at Never release or drive a truck that has a tempt to move the vehicle until brake air brake discrepancy no matter how mi pressure in both circuits is at least 100 nor until it has been repaired or psi 690 kPa Failure to follow this pro corrected Failure to repair brake dis cedure may lead to uncontrolled vehicle crepancies can result in compromised movement and cause severe personal in brake efficiency and may lead to loss of jury or death control of the vehicle resulting in severe personal injury or death General All Volvo vehicles are designed to meet or exceed all applicable federal brake stan dards and regulations They use a dual circuit compressed air system It consists of two independent brake systems that use a single set of brake controls Each circuit is supplied by its own compressed air tank Both air tanks receive compressed air from the same supply tank wet tank and are charged with equal pressure The two cir cuits are interconnected for the parking brake system Air pressures in the two circuits are moni tored by two pressure gauges on the right side of the instrument cluster The primary rear brake circuit gauge is marked with an R within a symbol and the secondary front brake circuit gauge is marked with an F within a symbol The two pointers should register equal or nearly equal pres sure By observing
171. l page 88 Mirror Heater page 88 Right Turn page 86 Transmission Temperature page 92 Check Transmission page 92 Traction Control System page 92 Wait to Start Not used Transmission in Neutral page 92 Water in Fuel Not used Instruments and Controls 73 Graphic Display Telltale Overview wo N SmArANI An RA Voltmeter page 162 Engine oil temperature page 159 Transmission oil temperature page 125 Preheating active page 78 Acknowledged warning page 130 Alarm clock on page 167 PTO engaged page 101 Cruise control engaged page 265 Airbag SRS page 63 10 11 12 13 14 15 16 17 W3003534 Coolant level page 126 Washer fluid level page 120 Engine airfilter clogged page 121 Too cold for engine brake page 289 Overheating instrument cluster page 120 Engine preheat fault page 249 Engine oil pressure page 76 Coolant temperature page 75 74 Instruments and Controls Left Instrument Section A Pyrometer option this page B Engine Coolant Temperature page 75 Engine Oil Pressure page 76 D Turbo Boost Pressure option page 77 E Graphic Display page 114 F Telltale Indicators page 77 W3003644 A Pyrometer option An engine pyrometer system indicates the exhaust temperature which helps the opera tor get the best efficiency from the engine Variations in engine load can cause the ex ha
172. l W3002596 see fifth wheel uncoupling on page 329 Mirror Defroster Telltale option The telltale lights up amber when the mir ror defrost switch is engaged Heater temperature is automatically regulated by an internal system in the mirror head W3000632 Instruments and Controls 89 Right Instrument Section L Forward Drive Axle Oil Temperature option this page Rear Drive Axle Oil Temperature L option this page Fuel Level Gauge page 90 Application Air Pressure option page 90 OR Air Suspension Pressure option page 90 P Front Brake System Air Pressure page 91 EO ees a e R Rear Brake System Air Pressure page 91 W3004407 Warning Telltales page 92 L amp M Forward amp Rear Drive Axle Oil Temperature option The gauges are connected to temperature senders installed in the axles Normal oper ating temperature range is up to 250 F 120 C If average oil temperature consis tently goes above 250 F 120 C more frequent oil changes are needed or an oil cooler could be installed A sudden increase in oil temperature that is not caused by a load increase 3003634 may indicate mechanical failure Bring the vehicle to a safe stop where the problem can be checked Do not operate vehicle until correcting the problem 90 Instruments and Controls N Fuel Level Gauge The gauge is connected to a sending unit in the fuel tank There is only one send
173. l and defroster page 174 If equipped check mirror heater Check condition of warning triangles fire extinguisher and flares page 68 Adjust the seat page 195 Check mirror adjustment Check safety belts for function and damage page 55 Apply service brakes After initial drop pressure should hold steady or increase slightly with engine at idle Check steering wheel for excessive free play Check for loose items in the cab Se cure them if necessary 40 Pre Trip Inspection and Daily Maintenance Hooking Up To Trailer Hook up Preparation e Check kingpin and mounting plate on trailer free from wear bends or dam age e Chock trailer wheels Fifth Wheel Or Trailer Hitch e No visible space between fifth wheel and trailer page 326 e Locking jaws around the shank and not the head of kingpin page 326 e Release lever properly seated and safety latch lock engaged page 327 e Check all connections to dolly or trailer hitch and safety chains are se cured e Check function of trailer air supply valve and trailer brakes Sliding Fifth Wheel e Check that fifth wheel is not so far forward that the tractor frame will strike the landing gear during turns NOTE Refer to the trailer manufacturer s Pre Trip Inspection and Daily Maintenance 41 manual for specific information on the trailer checks Step 9 Trailer Front Area Air and Electrical Connections Glad hands properly
174. l maintain this new temperature within the ability of the temperature control NOTE Changing from manual to ATC control or the other way makes the air out put temperature change 5 to 10 degrees A small correction to the temperature control is needed after the change has been made 182 Heating and Air Conditioning Air Vents Closed B Open C Lateral Air Flow J Vertical Air Flow When heating the cab all vents should be closed However the vents on the outer parts of the dash can be used for defrosting A the cab door windows When operating the o B air conditioning all air vents should be completely open and the air flow directed upward W8001150 Heating and Air Conditioning 183 Sleeper Climate Unit General The sleeper cabs have an optional A C and heater unit that is located in the passenger side luggage compartment The sleeper unit operates from the same heater and air con ditioning supply as the main unit The heater can be operated independently from the main unit as long as the engine is run ning For the air conditioning to operate the engine must be running the air condi tioning button must be pressed in and the fan control must be set at least for speed 1 on the main control panel Air is taken from the sleeper area through a filter in the lower bunk support wall and heated or cooled in the underbunk unit Outlet air can be directed with the vents in the side walls the illustration shows t
175. ld The opening is normally covered by a plate To access the opening remove the two screws using a T30 Torx screwdriver Re move the cover plate The hood latch can now be accessed through the hole Operate the latch manu ally by pushing the lever in toward the engine Do the same on the other side Vehicle Access 31 W8002389 W8000981 32 Pre Trip Inspection and Daily Maintenance General N DANGER Before working on or inspecting a vehi cle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in un expected vehicle movement and can cause serious personal injury or death Safety is the most important and obvious reason for doing a pre trip inspection Fed eral and state laws require inspection done by the driver Federal and state inspectors also inspect commercial vehicles An un safe vehicle can be placed out of service until the driver or owner corrects the deficiency Owners and operators should fa miliarize themselves with sections 49 CFR 396 11 and 396 13 concerning Federal re quirements for vehicle inspection Certain other laws may also apply Section 49 CFR 396 13 states that all motor carrier drivers must complete a written re port at the end of each work day for each vehicle operated covering most of what is covered in the pre trip list The report should list all defects or deficiencies dis covered by the driver Doin
176. lt instruction guides for suspension and sta tionary seats Use the proper guide for your type of seat and follow the instructions very closely It is vitally important that all components are mounted back in the same positions as the original components that were removed This will maintain the de sign integrity of the mounting points for the safety belt assembly 60 Additional Safety Features Comfort Clip Operation When provided the comfort clip is located on the shoulder strap just below the D ring When adjusting the comfort clip the fol lowing procedure must be followed for proper adjustment 1 Pull out only enough webbing to allow slight pressure to the shoulder and chest Allow no more than a 1 in 25 mm slack when measured be tween the chest and the belt 2 To activate the clip mechanism feature lift the lever up to clamp the webbing in place NOTE When the safety belt is not in use the clip should be in the open position to allow the seat belt to retract to its proper position Also make sure that the adjust ment of the comfort clip does not interfere with the operation of the safety belt W8002388 Open position Always adjust the clip so that there is a maximum of 1 in 25 mm of slack be tween the belt and chest about two fingers width If a larger slack is allowed the ef fectiveness of the safety belt is decreased in the event of a collision
177. lt language Fleet limit r min Fleet limit speed Fleet fuel target Amperemeter calibration Fleet ID Reset applicable for several functions Status test Password config When the start key has been in stop posi tion for more than 60 seconds or if the batteries have been disconnected the pass word must be entered again The password protected menus are de scribed in the Service Manual Instrument VN 2 99 Order information can be found on page 341 Main Menu Gauge When the menu GAUGE has been se lected you switch between the various sub menus with the up down buttons e TEMPERATURE ENGINE OIL e TEMPERATURE TRANSMISSION OIL Option e VOLTMETER Temperature engine oil MENU GAUGE TEMPERATURE EN GINE OIL The engine oil temperature is shown as in the diagram If the sensor data for Temperature engine oil is not available the symbol is shown as well as the text NO DATA Information message Yellow A INFO telltale If the engine oil temperature becomes too high an information message is shown au tomatically with the text HIGH At the same time the yellow INFO telltale un der the display lights up Esc acknowledges the info message Graphic Display 159 4 T3008830 aF T3008830 T3008830 185 F NO DATA HIGH 210 F ZN NFO T3008860 160 Graphic Display Temperature transmission oil option MENU GAUGE TEMPERATURE TRANS
178. ltales Coolant Level N DANGER RPH T3008851 Failure to take necessary action when the ASTOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked The telltale is shown if the coolant level is too low During check Pre trip option a text message is shown if the level is too low Engine Oil Pressure N DANGER Failure to take necessary action when the ASTOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked Shown when the engine oil pressure is too low The LED in the gauge lights up to gether with the telltale and the buzzer also sounds Depending on the engine manufac turer s program in the ECU the trip point may differ slightly for different engines Coolant Temperature N DANGER Failure to take necessary action when the ASTOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked The symbol is shown when the coolant temperature is too high Graphic Display
179. maged It should be secured against tangling dragging and chafing Brakes e Condition of brake drums With brakes released look for a noticeable gap be tween lining and drum This check can not be made if dust covers are in place e Condition of brake hoses check for any chafing e Check brake chamber mounting bolts and brackets e Check slack adjusters and chamber push rod travel With brakes applied or released look for conspicuously dif ferent positions of the slack adjusters e Check spring brakes 44 _ Pre Trip Inspection and Daily Maintenance Step 14 Left Side of Trailer Area Landing Gear or Dolly Area e Fully raised no missing or damaged parts e Crank handle present and secured e If power operated no air hydraulic leaks Spare Wheel s e Spare wheel securely mounted in rack with no damage to rack e Tire and wheel condition adequate for a Spare proper size properly inflated Lights and Reflectors e Trailer side clearance lights clean op erating and proper color e Reflectors clean and proper color Frame and Body e Frame and crossmembers not bent cracked damaged or missing e Proper placarding e Body parts not damaged or missing Before Leaving the Parking Area Remove chocks from the wheels Test trailer hook up by slowly pulling while applying the trailer brakes with the trailer brake hand control valve Test the service brakes before leaving the parking
180. mode is engaged At all other times the TCS system operates in the background without indication The system does not have an on off switch See page 287 for more information The TCS only operates at speeds lower than 25 mph 40 km h The system detects wheel spin by comparing wheel speeds and controls the spin by using the brake system to transfer power to wheels with greater traction Under circumstances where all drive wheels are spinning the system sends a signal to the engine control unit to reduce power The TCS includes a TCS mud snow switch for turning the system off to increase wheel spin This function may be desirable in deep snow or mud to keep the vehicle from bogging down To operate press in the bottom part of the switch The switch stays in this position and the TCS telltale light blinks to indicate that the mud snow mode is engaged To re turn to normal TCS operation press the bottom part of the switch again and it will return to rest position ons atcs as W3000962 W3001336 93 94 Instruments and Controls Auto Neutral Telltale The Auto Neutral Telltale is for the Allison WTEC III transmission The green indica tor lights up when the transmission is in auto neutral Auto neutral is activated just before the vehicle comes to a complete stop W3004308 less than 1 5 mph 2 5 km h The gear is re engaged shortly 1 2 seconds after the brake pedal is released Allow for the gear
181. must not exceed a 10 amp draw Before connecting any elec trical accessory make sure it is made for 12 V operation The top tray is available as a CB mount with a strap to hold different size radios se curely in place W3002001 W8001876 12 Volt Power Outlets There are a number of 12 V outlets that can be accessed in the cab or the sleeper area On the dash there are cigar lighter and CB power studs as possible 12 V outlets In the VN 610 and VN 660 sleeper there is an unswitched power outlet on the sleeper control panel The outlet is covered by a cap that is pulled out for access The outlet is made for a cigar lighter type plug On the panel is also a cigar lighter that can be used for an additional 12 V outlet In the VN 770 sleeper there are the same panel mounted outlets as for the VN 610 as well as outlets in the cabinets For the driver side cabinet the two outlets are switched The switch is located on the sleeper control panel and is used for switching off a refrigerator if the vehicle is parked for a longer time Outlets in the passenger side cabinets receive unswitched power Normal acces sories for this cabinet will have on off switches of their own The cabinet 12 V outlets have cigar lighter type plugs Electrical System 305 a W3002430 W3002333 W3002000 306 Electrical System 120 Volt System and Outlets The VN 610 VN 660 and VN 770 are available with an opti
182. n The clock is now set 226 Cab Interior and Sleeper Alarm Function When the alarm function is selected the following can be operated Setting Alarm Time D A D A D A Press the MODE button until the bell symbol appears in the window Press the SET button The hour digits will begin to flash Set the alarm time hour with the up or down arrow button Press the SET button to accept the hour The minute digits will now start to flash Set the alarm time minute with the up or down arrow button Press the SET button to accept the minute The display ON now appears The set time can now be selected as either the alarm ON or alarm OFF This is alternated by pressing one of the arrow buttons To accept the alarm ON or OFF press the SET button The mode now returns to clock function If the alarm is set a solid bell symbol appears in the display If no alarm is set only the time will be displayed When the clock reaches the set time for If the alarm time setting has not been com alarm and providing the alarm was set a pleted the display returns to the clock buzzer sounds intermittently for 60 sec function 30 seconds after the last button onds To turn the buzzer off press any was pressed button once Switching Off Alarm Buzzer a The buzzer is switched off by pressing any of the buttons The alarm must v be re activated before the buzzer will operate again Cab Interior and Sleeper Smoke
183. n can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Instruments and Controls 77 D Turbo Boost Pressure option The gauge indicates intake manifold pres sure on the engine The pressure is generated by the turbo Boost pressure should be the same at a given engine tem perature speed and load Turbo boost pressure will vary for different engines and vehicle models By monitoring the gauge the operator can avoid engine problems W3003631 F Telltale Indicators Left Section 1 Engine preheat telltale page 78 Gl A N nro As E 2 Caution telltale page 79 4 No Charge telltale page 81 2 S Oo Stop telltale page 80 78 Instruments and Controls 1 Engine Preheat Telltale The amber telltale will light up when the intake manifold preheater is operating The heater is used for better cold starts Opera tion time of the heater can vary in several steps from 0 to 50 seconds depending on coolant temperature and outside air temper ature On cold mornings the preheater will be on for the maximum 50 seconds When the ignition key has been turned to the pre heat position the preheater coils in the intake manifold are activated to warm the intake air Once the engine is started the preheater may be re engaged to assist in a quicker engine warm up See page 249 for information on using the pr
184. n cause serious personal injury or death W2002049 46 Pre Trip Inspection and Daily Maintenance If the vehicle is equipped with an aero dynamic bumper do not step on or press in between the bumper and the wheel Breakage or damage may result Keep yourself clear of all moving or hot engine parts A hot engine can cause se rious burns Check oil level in the engine with the dip stick The oil level should be between the minimum and maximum marks on the dip stick Do not overfill or underfill oil Prema ture wear or component damage may result if you do W2002047 See the Operator s Manual Maintenance and Engine for correct types of oil used in Volvo engines To add oil to the engine remove oil cap on the valve cover and fill through the hole Make sure the oil added is the same type of oil that is in the engine The wrong type of oil could accelerate wear on engine if not suited for application W2002048 Pre Trip Inspection and Daily Maintenance Check fluid level in the clutch fluid reser voir Fluid level should be between the level marks on the reservoir If fluid needs to be added use brake fluid DOT 4 Check level in the windshield washer reser voir If washer fluid needs to be added use a commercially reputable washer fluid that has good cleaning capability and does not freeze in cold weather Total reservoir capacity is 3 3 gallons 12 5 liters An indicator will a
185. n Preheating See page 249 for more information on the Volvo engine preheater T3008841 122 Graphic Display Transmission Oil Temperature This telltale lights when the transmission oil temperature is too high It is shown with a text information about the temperature See page 125 for more information Charging System This telltale lights when there is a problem in the charging system It is shown with text information of the charging system sta tus The voltage is shown together with the message TOO HIGH See page 162 for more information Engine Oil Temperature This telltale lights if the engine oil temper ature becomes too high It is shown with the text TOO HIGH The engine power is derated The temperature limit for activa tion varies for different engines See page 159 for more information Yt F T3008831 E T3008832 qat T3008830 Graphic Display 123 Text The yellow INFO telltale lights up and information text is shown on the display The text contains information on where the fault has occurred as well as the type of fault applies to the data link Factory installed equipment CHECK ENGINE NEXT STOP ZN NFO T3008860 Specific data link fault CHECK ENGINE DATA LINK T3008860 124 Graphic Display Data link broken CHECK DATA LINK BROKEN T3008860 Not factory installed equipment The following can be shown if equipment has been added by a
186. n severe per sonal injury or death The restraint netting can be used for secur ing loose articles Any loose articles that can shift in the cab during hard cornering or braking should be kept restrained Fasten the restraint by connecting the buckle with the latch Make sure the belts are not twisted Test the latch connection by pulling on the belt If they come apart reconnect and test again If the connection can not be made replace the belt before us ing the bunk for sleeping during driving To loosen the restraint press the red release button on the latch 1 Restraints should be properly stored when not used Having the restraint laying loose in the cab can be a source for unintentional snagging 53 W8000895 W8002475 54 Additional Safety Features Safety Restraint VN 420 VN 610 and VN 660 The restraint has latches in one end and buckles in the other so it can only be in stalled one way Connect the restraint to the back wall and the buckles on the floor Con nect the side tethers and adjust the straps to form a tent over the bunk VN 660 upper bunk does not have the tenting feature W8002039 Safety Restraint VN 770 Connect the restraint to the back wall first The wall connectors are located in the stor age units Connect the lower part of the restraint to the lower buckles Connect the side tethers and adjust the straps to form a tent over the bunk NOT
187. n the driver s side and also a fixed seat Each of the seats are described on the pages that follow N DANGER All adjustments are to be made while W8002742 the operator is seated and the vehicle is National Comfort Seat stationary Do not adjust the seat posi tion while driving the vehicle Failure to follow this warning can result in loss of vehicle control which can result in seri ous personal injury or death in the event of a crash Before adjusting or fastening the seat belt move the seat forward or rearward and ad just the seat height as necessary Sit erect and adjust the seat cushion and seat back to obtain a comfortable driving position T8006503 Volvo Comfort Seat 195 196 Seats National Standard Seat Adjustments 1 Backrest tilt By rotating the round handle the backrest recline angle can be adjusted within 12 degrees Cushion front tilt and length Pulling the handle up and out adjusts the tilt and length of the seat cushion NOTE Support body weight with your feet while adjusting Fore and aft movement Press the lever sideways to unlock the seat Move seat fore or aft to a new position Ride height adjustment Push the up per part of the switch up to increase ride height Push the lower part of the switch to deflate the airbag and lower the ride height Lumbar support adjustment Push the upper part of the switch to inflate the support for a firmer support Push the lower
188. nction ap The modes are arranged in a continuous pears in the window Display Mode Symbols The three symbols illustrated below can be shown on the display A Symbol showing that the alarm function is selected See page 225 for information to operate clock alarm jti Symbol shows that the parking heater is on See page 191 for information on direct and rapid start Symbol shows that the time delay start of the parking heater is on See page T 191 for information to set start with time delay Heating and Air Conditioning 191 Rapid Start Stop Of the Parking Heater To use the rapid start stop function of the tion works independently of the timer timer there is no need to access the correct operation function by the MODE button This opera FON To start the parking heater manually press in both the up and the down but n m tons at the same time for at least 3 seconds 4 The heater will now run for 8 hours and then it switches off automatically FF peers To stop the parking heater manually press in both the up and the down but 4 7 tons at the same time for at least 3 seconds Parking Heater Direct Start With Set Operating Time jti Symbol for direct start of parking heater The symbol flashes until the func tion is changed To select the function to start the parking heater use the MODE button to switch between functions until the direct start symbol appears SE Press the SET button The hour digits s
189. nding on the model there are some important features built into the unit Take the time to read the manufacturer s manual to be able to operate functions such as ra dio wake up alarm snooze function and theft deterrent coding W3002006 CD Changer A CD changer is available for VN 660 and VN 770 It is located in the passenger side overhead storage The power amp is located in the same storage There can be 4 to 9 speakers in the cab The subwoofer is lo cated in the lower bunk support Read the manufacturer s manual for opera tional information W3002428 W3002429 234 Communication and Entertainment Communication Equipment CB Radio There is an optional platform provided for a CB radio on top of the dash The unit is held in place with a strap which can ac commodate a variety of sizes For electrical hook up see page 304 The CB Radio can also be permanently mounted directly above the radio When the optional switch panel is removed a DIN standard radio mount is available W8001876 Telephone There is room on the dash for a mobile telephone This can be hooked up to the multiplex box If the vehicle is delivered with a multiplex box the connecting end of the telephone coaxial cable should be located at the lower dash cover Road Relay The Road Relay is an engine communica tion tool that allows the driver to have fuel consumption time and mileage readouts and also programmed reminde
190. ngine The Volvo engines are equipped with a warmholding device EPG Exhaust Pres sure Governor to keep engine at normal operating temperature to prevent incom plete combustion even at idle Engine Start and Operation 261 Low Idle Adjustment If the engine coolant temperature is above 122 F 50 C the vehicle is stationary en gine running accelerator released parking brake on and the PTO is not engaged the engine low idle speed can be adjusted with the use of the cruise control function W3002499 1 Set the cruise control switch to the ON position 2 Depress the foot brake pedal Hold it down during the entire procedure 3 Move the cruise control switch to the N DANGER RESUME position and hold it there Before setting the idle apply the parking for four seconds Release the switch brakes and place the transmission in The engine speed will drop to the de neutral Failure to do so can result in un fault low idle expected vehicle movement and can 4 The idle speed is adjusted up with the cause personal injury or death SET switch Each time the SET switch is pressed momentarily idle speed will increase approx 10 r min the speed cannot be increased above the maximum allowed by the engine manufacturer 5 The idle speed is adjusted down with the SET switch Each time the SET switch is pressed momentarily the idle speed will decrease approx 10 r min the speed cannot be adjusted below the low i
191. ngpin w9000494 1 Kingpin lock air release switch 2 Danger Fifth Wheel Instructions 317 Fifth Wheel Kingpin Lock Release Switch Operation N DANGER Activation of the kingpin lock release switch ONLY unlocks the kingpin latch mechanishm To relock the latch mecha nism you MUST pull forward and then back up to re engange the kingpin lock mechanism Failure to follow these in structions can result in separation of the trailer from the tractor causing personal injury or death Park the vehicle and apply parking brake for tractor trailer Put gearshift in neutral and chock trailer wheels Lower trailer landing gear to ground Disconnect air electric lines to tailer To release the fith wheel kingpin lock push the switch up This will release the locking mechanism Once acti vated the switch will not relock the fifth wheel kingpin locking mecha nism Release parking brake and drive trac tor 12 inches away from the kingpin Deflate air suspension by pressing bot tom of suspension switch After suspesion lowers pull clear of trailer and reinflate suspension See Suspension Level page 111 The fifth wheel kingpin lock will only relock if you follow the complete re coupling procedures See Trailer Coupling Procedures page 323 318 Fifth Wheel Instructions Safety Information Follow the instructions on the advisory la bels attached to the various manufacturers fifth wheel
192. ning there is no lubrication in the transmission T0006670 Axle shafts must be removed if the vehicle is to be towed at speeds over 25 mph 40 km h or for a long distance Openings should be covered to prevent loss of oil and entry of dirt and grit Where oil lubricated bearings are used openings should be thor oughly sealed with metal discs and new gaskets before towing If a vehicle with air suspension is lifted by the rear frame member there is a risk that the air springs will separate from the spring plates When towing has been completed do not under any circum stances use your hands to reposition the air springs There is a great risk that your hand will be caught between spring and plate causing personal injury 336 Emergency Information Do not tow a vehicle backwards when equipped with roof air fairings The fair ings act as an air scoop and may break off Failure to follow this warning may lead to personal injury and vehicle dam age Vehicles with air fairings are tall Make sure that the total height of the vehicle when it is raised up behind the wrecker does not exceed the maximum allowed height for local underpasses Failure to follow this instruction may lead to per sonal injury and vehicle damage The vehicle may now be towed It is rec ommended that a wrecker with a lift bar is used since the service brakes will not func tion The system must be filled with air to release the parking
193. ntact you if necessary Volvo Trucks North America Inc Att Vehicle Registration Dept P O Box 26115 Greensboro NC 27402 6115 United States of America 2 General Information Do Not Remove this manual from the ve hicle It contains important operational and safety information that is needed by all drivers and owners of this vehicle This Operator s Manual covers Volvo VN series vehicles manufactured by Volvo Trucks North America Inc with any of the following designations VNL42T VNM42T VNL42 VNM42 VNL64T VNM64T VNL64 VNM64 L long hood M medium hood T tractor Explanation The first number after the model designation represents the total num ber of wheels hubs per vehicle The second number represents the number of wheels hubs that drive the vehicle Each model designation also carries a suffix which identifies the cab type This manual together with manuals for specific components for example Volvo engine Cummins engine Eaton transmis sion etc contain important information to be able to operate this vehicle safely They contain advice and instructions which will enable you to get the operating economy and performance that you expect from this quality vehicle All information illustrations and specifica tions contained in this manual are based upon the latest product information avail able at the time of publication If any questions arise concerning the current sta tus of Federal or stat
194. ntrol buttons on the wiper stalk pressed down for at least 1 second The menu re mains active for 30 seconds after the last depressing of the button The alarm clock cannot be set while driv ing but the buzzer which sounds for the alarm call can be switched off see page 168 Clock MENU TIME DIST CLOCK Shows the current time To set the time for mat 12h or 24h see page 134 Setting 1 To set the clock press SELECT when you are in the menu TIME DISTANCE and the clock function will be shown 2 Set the hours with the up down buttons Confirm the choice with SE LECT 3 Set the first digit in the minutes with the up down buttons Confirm the choice with SELECT Graphic Display 165 166 Graphic Display 4 Set the second digit in the minutes with the up down buttons Confirm the choice with SELECT 5 Set the AM PM if the time format is 1 2 pd 00 12h with the up down buttons Con firm the choice with SELECT Cancel setting When setting hours Esc cancels the setting and the time is shown according to the pre vious setting Pressing Esc after setting the minutes or af ter setting the AM PM moves the cursor back to the previous selection Ignition key in the off position When the ignition key is in the OFF posi tion if setting the clock takes more than 30 seconds between pushing the buttons the time which has been entered then applies Alarm clock MENU TIME DIST ALARM CLOCK Setting the
195. older NOTE In poor ground conditions it may be necessary to provide a stable base for the landing gear 332 Fifth Wheel Instructions Disconnect the light cord and air brake lines Use the dummy air couplings to keep foreign material from entering the brake lines Unlock the fifth wheel NOTE If the operating rod is too difficult to pull back the tractor up slightly to re Z w ve X ences i U i M lieve any kingpin load against the fifth NN Uai tod ny kingp g N ess Sk wheel jaw ZN x W9000275 Release the tractor park brakes and slowly drive the tractor out from under the trailer Let the trailer slide down the fifth wheel and pickup ramps W9000239 After the trailer is uncoupled the fifth wheel will be in the open position The op erating rod will drop and can be moved around freely W9000203 Fifth Wheel Instructions 333 Operating the Volvo Slider The trailer must be stopped and the trailer brakes locked or damage to the tractor and or trailer may result from un controlled sliding of the fifth wheel Stop the tractor and trailer in a straight line on level ground Lock the trailer brakes by pulling out the Trailer Supply knob Release the slide locking plungers by mov ing the switch to the UNLOCK position press down the latch and push in the bot tom part of the switch Check to see that both of the slide plungers have released If the plungers
196. on Switch The ignition switch is located on the right side of the steering column just under the steering wheel Standard equipment is a normal ignition switch A steering wheel lock is available as an op tion When the key is removed it actuates a detente pin that prevents the steering shaft from turning NOTE The vehicle is delivered with 2 identical keys If more keys are needed order them through your Volvo Truck au thorized dealer The keys are laser cut and require a special machine for copy ing available through your Volvo Truck dealer Record the key code and keep in a secure place A new key can be made using the key code if the keys are lost W3000976 The ignition positions are O Off T I Radio Accessories M I S II Drive II 1 2 Preheat Volvo engine only Ill Start The ignition switch has a restart inhibitor locking out the start position after one try which means that the key must be turned back to O before a new attempt at starting can be made EG The key can only be removed when in the O or Off position W3001302 For full starting instructions see page 245 Engine Start and Operation Cold Weather Start and Operation Volvo Engine Cold Start NOTE These cold start instructions are for Volvo engines only For other engine makes see the manufacturer s handbook N DANGER Do not use ether or similar starting aids in a Volvo or other engine with a pre heater The Volvo eng
197. on of brake air hose Check brake chamber mounting bolts and bracket Check slack adjuster and chamber pushrod travel Condition of Front Axle and Steering Sys tem Left Side No loose worn bent damaged or missing parts Under Hood Left Side Check coolant hose condition Check condition of fan drive belts Check engine and surrounding areas for coolant oil and fuel leaks Check wiring harnesses for signs of damage Step 2 Front Of Cab Area Condition of Windshield Check for damage and clean if dirty page 48 Check windshield wiper arms for proper spring tension Check wiper blades for any damage dead rubber and securement to arm Lights and Reflectors Lower hood and inspect parking clearance and identification lights on hood and cab They should be clean operating and of the proper color Reflectors clean and proper color Turn on headlights High and low beams should be operating and lenses clean If equipped check daytime run ning lights Left and right front turn signal lights clean operating and proper color Raise hood Grille Check that charge air cooler and radia tor or bugscreens are clean and undamaged Step 3 Right Side Of Cab Area Right Front Wheel Check condition of wheel rim Espe cially look for cracks missing lockrings bent or broken studs clamps or lugs Check condition of tire properly in flated no serious cuts bulges tread wear or an
198. on of brake drums With brakes released look for a noticeable gap be tween lining and drum This check cannot be made if dust covers are in place e Condition of brake hoses check for any chafing e Check brake chamber mounting bolts and brackets e Check slack adjusters and chamber push rod travel With brakes applied or released look for conspicuously dif ferent positions of the slack adjusters e Check spring brakes Step 6 Rear Of Vehicle Area Frame Area Frame or cross members not bent cracked or otherwise damaged or missing Check that air tubing and electrical lines are properly secured to the frame with no damage or chafing Lights and Reflectors Tail lights brake lights and turn signal lights operating clean and proper color Pre Trip Inspection and Daily Maintenance same oo gt N Tassy Step 7 Coupling System Area Fifth Wheel Securely mounted to the frame No missing or damaged parts Check that trunnion and plate are properly lubricated page 318 Sliding Fifth Wheel Mechanism not worn bent damaged or parts missing page 320 Properly lubricated All locking pins present and locked in place If air operated no air leaks Air Tubing and Electric Lines Visible From This Point Should be secure from dangling Both air lines and electric line should be free from damage oil and grease 37 W0001230 Step 8 Left Saddle Tank and Left Rear Vehicle Wheel
199. on shifts gears Transmission Mounted PTO The vehicle should be stopped before en gaging power take off Engage the PTO by depressing the clutch pedal and pressing in the bottom part of the switch Release the clutch pedal to start the PTO One or two PTOs can be run at the same W3001994 time Applications change depending on customer needs and components 102 Instruments and Controls Engine Mounted PTO The engine should be running at low idle and the vehicle should be stopped or run ning at very low speed before engaging power take off Engage the PTO by press ing in the bottom part of the switch The PTO is now in operation and hydraulic flow can be regulated by the engine speed W3001993 Instruments and Controls 103 PTO Speed Adjustment Have the PTO engaged before adjusting the speed For the PTO speed adjustment to function the Cruise Control or idle adjust can not be active brake and clutch pedals must be released and vehicle speed must be under approximately 5 mph 8 km h W3002499 To set engine speed 1 Set the PTO CC switch in the ON po sition 2 Use the accelerator to increase engine speed 3 Momentarily press the SET or SET switch to set current engine speed To increase decrease engine speed 1 Press and release the SET or SET toggle switch to increase decrease speed in increments increment size depend on programmed value 2 Press and hold the SET or SET tog gle swit
200. on the parking brake application Any time the parking brake telltale is on the DRL is deactivated W3000627 N DANGER Never exit your vehicle unless the park ing brake is set Failure to do so can result in unexpected vehicle movement and cause personal injury or death For proper use of the parking brake see page 278 88 Instruments and Controls ABS Telltale Tractor and Trailer The telltale lights up amber if the Anti Lock Brake System ABS senses a 5 problem under the following conditions g 1 The system will go through its self test when the ignition switch is turned on and the telltale should continue to O be on The light should go out when the vehicle speed reaches over approx imately 7 mph 11 km h If the aa telltale stays on at higher speed there W3000905 is a problem with the ABS 2 The ABS telltale lights up during driv ing The ABS self test has detected a fault in the system The vehicle can still be driven with a prob lem in the ABS However the ABS will not be operating and standard air braking is in effect For more information see page 285 The trailer ABS telltale is in effect for ve hicles manufactured after February 2001 Air Suspension Telltale The telltale lights up amber when the sus pension leveling valve is activated As long as the switch is activated the suspension is lower than normal and the telltale is on For proper use of the suspension level contro
201. onal 120 V service used for longer parking while still living in the vehicle The 120 V service is supplied from outside sources N DANGER When parked on wet ground avoid us ing an external power source to connect the cab power plug Water is a conduc tor of electricity Personal injury or death resulting from electrical shock can occur in wet conditions To hook up the service there is a socket 1 lower illustration located under the driver side door If the vehicle is equipped with an engine heater the socket for cab power is on the bottom Power goes through a breaker box 2 lo cated on the front wall in the driver side luggage compartment On the right is an ON OFF switch and on the left is the ground fault interrupter The controls are also reached from the inside of the cab through the hatch under the mattress or cushion W3001999 Electrical System 307 From the breaker box power goes to three outlets One is on the driver side bunk box 4 There is one outlet in each tower cabi Yy net in the middle compartment 3 and 5 q1 o W3002367 308 Electrical System Changing Headlight Bulb The headlight bulb can be accessed from the rear of the headlight assembly Raise the hood Remove the clamps from the back of the headlight box by lifting and pushing them to the side Remove the cover Remove the terminal from the back of th
202. operative the fan clutch Removing the fan shroud Engine Removing or altering engine speed pro gramming so as to allow engine speed to exceed manufacturer s specifications Modifying the parameters of the Engine Electronic Control Unit General Information Fuel System Removing or altering engine speed pro gramming so as to allow engine speed to exceed manufacturer s specifications Inner Fender Shields and Cab Skirts Removing shields or skirts Cutting away parts of shields skirts or dam aged or loose portions of shields or skirts 15 16 General Information Vehicle Data Identification and Labels It is extremely important that the correct vehicle model and serial number are given whenever replacement parts or service liter ature are ordered Using these numbers as well as giving the major component model and serial numbers will prevent delay and errors in obtaining the correct material Space is given on the rear inside cover of this manual for noting the main component model and serial numbers The full 17 digit Vehicle Identification Number VIN is shown on the Vehicle Identification label located in the door opening on the driver s side see next page The 8 digit chassis number is em bossed into the bottom flange right hand side of the frame rail and the top flange left hand side of the frame rail 42 inches 1065 mm back from the front edge of the frame rail The use of this number
203. or and Sleeper On the passenger side of the lower bunk there is a storage cabinet for items that do not need to be at hand at all times In the daytime this storage area is hidden by the backrest cushions Access to the luggage compartment is made on both sides through a hatch under the outer bunk cushions The hatches are secured with a rubber cord To open the hatch loosen the cord and pull up the hatch with it On the VN 660 there is a velcro strap to hold the lid in the open position In the front part of the cab roof there is ad ditional storage Load limits for the right and left sections are 5 lb 2 5 kg for upper shelf and 15 lb 7 kg for lower shelf Load limit for the center section side shelves and the center shelf is 3 Ib 1 5 kg each 211 W8001870 W8001873 W8001861 212 Cab Interior and Sleeper Sleeper Bunks General There is only one bunk available for the VN 420 For the VN 610 660 and 770 an upper bunk is available and a lower bunk is standard The bunks for the VN 420 610 and 660 cover the luggage compartment They are hinged for access to luggage from inside of the cab To gain access release the latch mechanism and lift by the edge of the bunk platform Gas springs aid in opening and closing the platform Support the bunk with one hand while releasing the latches Failure to support the bunk may lead to the bunk falling without control causing personal injury
204. ou will not be able to pull the knob out any further N DANGER Do not attempt in any way to disassem ble or tamper with the spring brake chamber The force stored in the spring if suddenly released can cause personal injury or death N DANGER Do not apply the parking brake while the vehicle is moving The rear wheels may lock up causing loss of vehicle con trol leading to an accident with personal injury or death Brakes Trailer Brake Hand Control N DANGER The trailer hand brake control is not a parking brake valve and must not be used as one This brake is not designed to hold the vehicle stationary Failure to follow these instructions can result in the unintentional movement of the vehicle and may cause personal injury or death The hand control valve for the trailer brakes engages the trailer brakes indepen dently from the vehicle brakes The valve can be fully or partially engaged but in any partial position it will be overridden by a full application of the foot brake valve To supply air to the trailer brakes to slow the trailer down pull the valve handle down The farther the handle is pulled down the more air pressure is applied to the trailer brakes Releasing the self returning handle releases the trailer brakes Air Tanks When draining the air tanks do not look into the area of the draining air Dirt or sludge particles may be in the air stream and could cause eye injury A
205. p 1 Left Side Of the Cab Approaching the Vehicle Check under the vehicle for oil fuel coolant leaks or other signs of damage Check body surfaces for signs of breaks or damage Preparation Open drain cocks on air tanks to let the tanks drain page 283 Chock wheels on vehicle and if hooked up trailer Close air tank drain cocks Start the engine and let the air pres sure build up to normal page 273 Stop engine Switch on parking lights and four way flashers page 99 Apply parking brakes page 278 Release the hood latches page 30 Raise hood Left Front Wheel Check condition of wheel rim Espe cially look for cracks missing lockrings bent or broken studs clamps or lugs Check condition of tire properly in flated no serious cuts bulges tread wear or any signs of misalignment valve stem not touching wheel rim or brake drum valve cap in place Check wheel bearing and hub no ob vious leaking on outside or inside wheel Verify correct oil level in hub Left Front Suspension Check condition of spring spring hangers shackles U bolts no cracks breaks or shifting Check shock absorber condition 34 Pre Trip Inspection and Daily Maintenance Step 1 Left Side Of the Cab cont Left Front Brake Condition of brake drum With brakes released look for a noticeable gap be tween lining and drum This check cannot be made if dust covers are in place Conditi
206. part of the switch to deflate the support Cushion rear tilt Rotate the lever to get different height positions NOTE Support body weight with your feet while adjusting Chugger snubber Moving the handle down isolates the seat from the fore and aft movement of the cab W8002745 Seats 197 National Comfort Seat Adjustments 8 10 11 12 13 14 Lumbar support adjustment Push the upper part of the switch to inflate the lower part of the 3 chamber support Push the lower part to deflate it Lumbar support adjustment Push the upper part of the switch to inflate the middle part of the 3 chamber support Push the lower part to deflate it Lumbar support adjustment Push the upper part of the switch to inflate the upper part of the 3 chamber support Push the lower part to deflate it Back rest side support Push the upper part of the switch to inflate the sup port Push the lower part to deflate it Seat cushion side support Push the upper part of the switch to inflate the support Push the lower part to deflate it Front seat cushion adjustment Push the switch up or down to choose height position Armrest angle adjustment Ratcheting armrest Set to desired angle WOM OO W8002744 198 Seats Volvo Standard Seat Adjustments 1 Fore and aft movement Press the con trol down to unlock the seat cushion Move seat cushion fore or aft to a new position 2 Cushion front tilt
207. peeds mean high fuel con sumption Jerky driving also increases fuel consumption when the vehicle is constantly accelerated and slowed down Avoid a higher consumption by steady even driving Refer to each engine manufacturer s opera tor s manual for information on the engine s optimum operating range Hill Driving Technique Use the inertia of the vehicle to go over the crest of a hill under reduced power Use gravity to help with acceleration when go ing down the hill Build up speed before reaching the next uphill High Speed With increasing speed comes an increasing wind resistance that negatively affects fuel consumption 243 244 Engine Start and Operation Starting the Engine Start Procedure NOTE For cold weather starting see page 249 These starting and operating procedures should be followed for all engines For more detailed information about design and function on a non Volvo engine read the Operator s Manual from the engine manu facturer NOTE Before starting the engine see Instruments and Controls starting on page 70 for detailed information on how the gauges and telltales work N DANGER lt i Do not use ether or similar starting aids in a Volvo or other engine with a pre heater The Volvo engine is equipped with a preheater Introduction of ether or other combustible material in the intake manifold could cause a fire or explosion resulting in severe property damage se v
208. per work procedure Failure to do so can damage the SRS sys tem to the point where it does not work any longer A warning label is located on the upper steering shaft There is also a label on the inside of the windshield that indicates the inclusion of an airbag to the vehicle safety features When equipped with an airbag a label about the correct procedure for protecting small children and protecting the driver is attached to the left hand overhead storage lid or back of sunvisor ATTENTION mr VEHICULE 4 SRS VEHICLE T8006843 VEHICULE SRS VEHICLE L VOLVO 5191946 T8006842 7 SRS T8006841 AWARNING DEATH or SERIOUS INJURY can occur eSt as far back as possible from the ar bag ALWAYS use SEAT BELTS and CHILD RESTRAINTS TOLE TMS W8002741 Additional Safety Features Any queries concerning the SRS system should be directed to a Volvo Truck dealer There is no maintenance required for the SRS system until the date stated on the warning label located on the left hand sun visor DANGER Never attempt to repair any part of the SRS system Any interference with the system may cause it to malfunction and result in serious injury or death Work on the system may only be carried out by an authorized Volvo Truck dealer To allow the SRS system to work as de signed e Never drive an SRS system equipped vehicle with the hands on the steering whe
209. perating the vehicle avoid ruts and obstructions which cause a binding condi tion on the sides of the front wheels Drive the vehicle out of the rut then turn the steering wheel If possible avoid turning the wheels while the vehicle is at a stand still as this places a considerable load on the power steering system and front axle 309 310 Power Steering Periodically check the power steering fluid reservoir and keep it filled to the proper level with the recommended fluid See the Operator s Manual Maintenance and En gine for more information There is also a filter inside the reservoir that needs to be changed every 12 months Adjustable Steering Column option The steering column is fixed as standard An adjustable steering column is available as an option The adjustment device is op erated by a pedal on the left side of the floor To make adjustments depress the pedal and move the steering column to the desired position and then release the pedal N DANGER Do not try to make adjustments to the W6000876 steering wheel while the vehicle is mov ing Make all adjustments before starting to drive to prevent loss of vehicle con trol and personal injury or death Axles Differential Locks The drive axle s may be equipped with differential locks The single drive axle will only have a wheel differential lock With tandem drive axles there could be both wheel differential locks and an int
210. ppear on the diagnostic display when there is approximately 1 4 gallons 5 3 liters re maining in the reservoir Check that windshield wipers and washer are working properly The windshield washer spray should cover the windshield well The wipers should clean the windshield in a couple of strokes and should not leave any streaks 47 W4000726 W8000985 W3000874 48 Pre Trip Inspection and Daily Maintenance If the windshield needs an overall cleaning use a long handled cleaning sponge and squeegee Clean the side windows in the same way with a long handled sponge and squeegee W1000070 Check all lights for proper function e Headlights e Daytime running lights e Parking and marker lights e Stoplights e Turn signals W3000953 NOTE Make sure that all fluid levels are at their proper levels If the fluids are not at their proper levels add as necessary Refer to the Engine and Maintenance Manual for information on what types of fluids are rec ommended for your Volvo vehicle Pre Trip Inspection and Daily Maintenance 49 When draining the air tanks do not look into the area of the draining air Dirt or sludge particles may be in the air stream that could cause eye injury Empty out the air tanks daily With the air system fully charged and with the engine shut off listen for air leaks W5000601 50 Additional Safety Features Safety Belts General N DAN
211. premature failure As soon as the vehicle is moving remove the foot from the pedal for complete clutch engagement Once the clutch is fully engaged heat and wear does not affect it W4000760 Do not shock load the drive line through rapid engagement of the clutch Extreme care should be taken when driving heavy loads up hills Always use the lowest gear when starting out under adverse conditions When operating a vehicle equipped with a clutch brake the clutch pedal should not be depressed more than halfway to the floor while shifting except when the vehicle is at a stop To re enter the low gear from neutral or reverse or to enter reverse gear from neutral or low the clutch should be depressed all the way to engage the clutch brake This stops the rotation of the trans mission input shaft and provides an easy quiet gear engagement 270 Clutch and Transmission Folding Gear Lever option Releasing Gear Lever To fold the gear lever follow this proce dure N DANGER Before releasing the gear lever apply the parking brakes and shut down the engine Failure to do so can result in un expected vehicle movement and can cause serious personal injury or death e Make sure the parking brakes are set vobs e To release the gear lever pull the lever in toward the seat and press on the knob downward in a straight line e Twist the lever counterclockwise while holding pressure on the knob When releasing th
212. r Step 4 Right Saddle Tank Area Right Fuel Tank s Securely mounted and not damaged or leaking Fuel lines secure and not leaking Check that shut off valves are open Tank s full of fuel Cap on and secure 36 Pre Trip Inspection and Daily Maintenance Condition of Visible Components Rear of engine not leaking Transmission not leaking If equipped with oil cooler check for leaks or that air to air cooler is not blocked Check drive shaft Exhaust system secure not leaking not touching wires fuel or air tubing Frame and cross members no bends cracks or breaks Air tubing and electrical wiring se cured against snagging and chafing Step 5 Right Rear Vehicle Area Dual Wheels One Or Two Axles Check condition of wheels and rims Especially look for cracks missing lockrings bent or broken spacers studs clamps or lugs Check condition of tires properly in flated no serious cuts bulges tread wear or any signs of misalignment valve stems not touching wheels rims or brake drums valve caps in place and no objects stuck between the wheels Check that both tires are of same type for example not mixed radial and bias type and that their circumferences are matched Check wheel bearing and hub no obvi ous leaking on outside or inside wheel Suspension e Check condition of springs leaf or air spring hangers shackles and U bolts e Axle alignment Brakes e Conditi
213. r page 99 Headlight Switch page 104 Driving Fog Lights option page 105 Instrument Light Dimmer page 113 Climate Unit Control Panel page 174 Hood Latch Handle page 30 Pneumatic Switches page 110 10 Cigar Lighter page 113 Operating Before driving this vehicle locate the in struments and controls and become thoroughly familiar with their operation After starting and when driving always check that the instrument readings are normal 11 12 13 14 15 16 17 18 19 20 W8002383 Ashtray Instrument Cluster Left page 74 Instrument Cluster Main page 82 Instrument Cluster Right page 89 Trailer Hand Brake Control page 283 Tractor Parking Brake page 278 Trailer Air Supply page 278 Radio option page 233 Optional Switches page 112 Right Switch Cluster page 106 NOTE Availability of gauges depends on chosen options All gauges and telltales may not be used in all vehicles Instruments and Controls 71 Instrument Cluster Overview Els Anse fea General The cluster is available in seven different configurations with the speedometer either graded in mph or km h The cluster con sists of three combined sections Left Section The left section can include pyrometer en gine oil pressure gauge engine coolant temperature gauge turbo boost pressure gauge and a graphic display for driver information See page 74 for gauge infor mation and p
214. r make sure the yel low AND red knobs are pushed in all the way before driving the vehicle Brakes 279 W5001114 Pol fill U ay W5001116 Correct Driving Position Both knobs fully in 280 Brakes There is also an engine shut down device in the EECU that shuts down the engine af ter a pre programmed time in order to save fuel This is activated when the yellow parking brake knob is pulled out There fore some drivers park and release the parking brakes using only the red knob to keep the engine running It is then easily overlooked that in a vehicle parked with both the yellow and red knobs activated only the red knob is pushed in by habit I A fill L g W5001117 Incorrect Parking or Driving Position Brakes 281 Spring Brake For Parking N DANGER Never leave the vehicle without being certain the parking brakes are set or that other precautions are taken to prevent the vehicle from rolling Failure to do so can result in serious personal injury or death The parking brake mechanism uses spring i EA pressure as a separate power medium to ap ply the service brakes on the driving axles The parking brake is released by the same A compressed air source used to apply the service brakes Since this brake is released by air pressure the system must be charged to at least 60 psi 420 kPa before the park ing brake may be released Th
215. r store flat items between the bunk and the cabi net refrigerator The air intake can be blocked which causes the heater to over heat and shut down Heating and Air Conditioning 189 General A fuel heated parking heater is available as an option It is located in the left hand lug gage compartment The heater provides automatically regulated heat that is dis tributed through its own vents into the sleeper section of the cab Timer Clock The heater is operated by a combined timer for the heater and a clock with built in alarm See page 225 for information to set the clock and alarm Thermostat To be able to regulate the temperature in the sleeper while the parking heater is op erating there is a thermostat for setting the desired temperature It is located in the sleeper panel close to the timer clock The thermostat control range is between 54 to 83 F 12 to 28 C The green indicator lamp lights up only W8002015 when the heater is operating 190 Heating and Air Conditioning Timer Clock Modes Timer Clock function Solid alarm symbol if set Parking heater time delay Flashing symbol Alarm function with dot Flashing symbol Parking heater direct start Flashing symbol without dot W8001916 The timer clock has four modes that can be loop To access the next mode press the accessed by pressing the MODE button MODE button until the correct fu
216. re engagement when ap plying throttle do not increase engine speed before the transmission has engaged If the engine speed is too high the trans mission will not engage When operating the vehicle on normal grades less than 4 a slight roll back can be experienced when the brake pedal is released and before the trans mission re engages NOTE When operating on severe grades more than 5 the transmission has a safety feature that can be used Before re leasing the brake pedal manually press the DRIVE key on the Allison gear selector and the gear is re engaged manually to as sist in preventing roll back Instruments and Controls 95 NOTE Before beginning to work make sure the vehicle ignition is switched OFF If possible adjust the steering column back Remove the two screws at the top of the instrument cluster and fold the cluster out and let it rest face down against the steering column so the bulbs are accessible Do not let the cluster be in the W3000842 face down position for more than maxi mum 15 minutes Damage to the gauges can occur by oil running out of them making the gauge reading inaccurate Do not use any other tools for changing the bulbs than the correct tool Using a pair of pliers could easily cause a short circuit if power is on thereby destroying the circuit board W3001306 96 Instruments and Controls A bulb change tool can be ordered from your Volvo Truck de
217. ressure switch that comes on if air pressure goes below 60 psi 420 kPa At the same time the buzzer will sound and the main warning telltale will come on This pressure drop warns the operator to make a manual emer gency stop before an automatic emergency stop is made W3000638 Master Warning Telltale W5000923 Brake System Controls The air compressor governor pressure reg ulator valve and reservoirs are control devices Their function is to build up maintain and control air pressure in the reservoirs This is so that pressure is held constant between the minimum and maxi mum range established for air brake operation The brake valve quick release valve brake chambers and slack adjusters are applica tion devices They distribute the air pressure and convert its energy into the me chanical force necessary to apply or release the brakes Foot Brake Valve The foot brake valve is directly connected to the brake pedal The valve gives a pro gressive output against the pedal travel This allows better control of the pressure in the first half of the pedal travel In the last half of the pedal travel the pressure output increase is faster The foot brake valve applies the service brakes incorporating both the primary and secondary air systems The primary system controls the rear brakes and the secondary system controls the front brakes The foot brake valve receives air from the com pressed air tanks Air pr
218. ri cated and the jaw is in the open position If the jaw is not in the open position eZee 5 Y lt use a pry bar to rotate the jaw to the cat A AZ TNN S open position The lock is spring loaded aS ii fa oS Keep hands away to avoid injury R i BON OY BOO Use a pry bar to open the fifth wheel jaw RS Pa if necessary ue S Make sure the plate is tilted downward to the proper position at the rear W9000236 324 Fifth Wheel Instructions Make sure the mounting of the fifth wheel to the tractor frame is tight and in good condition If using a sliding fifth wheel make sure the slide locking plungers are fully engaged Chock the trailer wheels Use two chocks both on the front and rear of the wheel on both sides of the trailer Back up close to the trailer centering the kingpin on the throat of the fifth wheel and STOP NOTE For tractors with air ride suspen sion make sure the suspension control switch is in the RIDE position switch pushed in at the top and the air springs are inflated W9000263 W3001341 Fifth Wheel Instructions 325 Connect the air brake lines and the electri cal power cord Make sure that any slack in the lines is supported so that the brake lines do not become entangled Set the trailer brakes by pulling out the Trailer Supply control on the dashboar
219. ring start up Engine damage and severe injury and or death from burns or explo sion can occur N DANGER Do not use ether or similar starting aids in a Volvo or other engine with The Volvo engine is equipped with a pre heater Introduction of ether or other combustible material in the intake mani FO een ap fold could cause a fire or explosion resulting in severe property damage se vere personal injury or death 260 Engine Start and Operation Idling All engines in the VN models are electroni cally governed engines The idle speed is pre programmed from the manufacturer Low idle speed is adjustable within certain limits for most engines between 600 to 750 r min See page 261 for more information The common belief that idling a diesel en gine causes no engine damage is wrong Idling produces sulfuric acid which breaks down the oil and eats into bearings rings valve stems and engine surfaces NOTE Avoid excessive idling If the vehi cle is parked for more than 5 minutes stop the engine An engine can burn from 0 75 to 1 5 gallons 3 to 5 5 liters of fuel per hour while idling During long engine idling periods the engine coolant tempera ture may fall below the normal operating range Incomplete combustion of fuel dur ing the warm up period can cause dilution of the oil in the crankcase formation of lacquer or gummy deposits on the valves pistons and rings and rapid accumulation of sludge in the e
220. ring brakes will apply and the trailer emergency system will be activated On vehicles equipped with the standard two valve system the operation of one valve to gether with the other permits the operator to select the desired functions described be low Red Valve Yellow Function Trailer Air Valve Sys Mode Supply tem Park Out System Park Out Trailer Charge In Normal Running In Bobtail W5000924 Parking Brake Release VN models have engines equipped with en gine electronic control units EECU These have two features that may impact the brake system One is the anti stall device in the EECU which senses torque demand and automatically controls the engine to com pensate and maintain speed On tractors equipped with parking brakes on only one axle the anti stall device keeps the engine from stalling allowing the driver to pull away with the brakes dragging This may result in overheated brakes and damaged wheel hubs Continual dragging of the brakes will cause brakes to overheat This may lead to wheel end fire To avoid overheating make sure both parking brake knobs are pushed in before driving off If the yellow knob is pulled out and the red knob is pushed in a condition is created where the trailer parking brakes are not ap plied and only the single drive axle brakes are applied In this condition the vehicle can be driven away Therefore it is very important that the drive
221. rs for service intervals The Road Relay should be per s manently mounted directly above the radio er HMAT BD e Collected data can be downloaded for use in a stationary computer where the data can be collected and compared over time W3002420 Communication and Entertainment Television All items within the cab must be secured before the vehicle is set in motion This includes but is not limited to drinks clothes books televisions etc In the event of a sudden stop or collision loose items could fly around inside the cab This could cause personal injury The VN 610 VN 660 and VN 770 are al ready equipped for TV with a pre installed antenna The TV should be installed in the passenger side cabinet where there is a standard 12 V connection or an optional 120 V connection To prevent the TV set from moving when the vehicle is driven the strap in the TV storage area should be clamped tight around the set If the strap comes loose from the buckle thread it as illustrated Ad just the strap so it is tight around the set and then clamp the buckle down to lock it in place The strap is wound around the TV as a loop through the holddown brackets Locate the buckle where it can be reached most easily W8002366 235 236 Communication and Entertainment There is an optional television speaker available located in the top of the sleeper switch panel Beside the speaker there is a
222. ry Sit erect and adjust the seat cushion and seat back for a comfort able driving position In the event of a collision a correct driving position maxi mizes the effectiveness of the safety belt There are both Federal and State laws gov erning the use of safety belts As laws differ from state to state make yourself fa miliar with the current rules W8001077 Tether straps are installed on all suspension type seats Tether straps help se cure the seat to the floor and are intended to restrain the seat and safety belt in case of an accident or sudden stop The tethers are not adjustable and do not need any adjustment W8001387 52 Additional Safety Features Operating the Safety Belt To fasten the safety belt pull the belt out from the retractor and insert the latch into the buckle Verify proper lock of the latch by pulling on the latch Adjust the slack by pulling on the top part of the belt until the lower part or the part that crosses the lap is snugly adjusted Re lease the top part and let the retractor pull the belt in a The lap portion of the safety belt should be worn low across the pelvic region hip i sodisss bone and adjusted snugly Never adjust the lap belt across the abdomen A push button on the buckle is used to release the safety belt latch by pushing in the button release on the buckle
223. s An operator s manual from the manufacturer is supplied with each fifth wheel and is provided in the Owner s pack age If the fifth wheel is equipped with a sliding mounting follow the advisory labels at tached to the component Also read the literature provided by the manufacturer N DANGER Always keep the fifth wheel plate well lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control that may result in serious personal injury or death A DANGER FOLLOW ATTACHED COMPLETE IE NOT PROPERLY COUPLED INSTRUCTIONS FURNISHED BY TRACTOR TRAILER COULD SEPERATE SERIAL NO AMERICAN STEEL FOUNDRIES 3 g XXOOXOXXO BEFORE OPERATING THIS FITH WHEEL x OPERATING HANOLE LATCH ARE IN LE AND SAFTY POSITION AS SHOWN EL CHICAGO ILLINOIS 60606 W9000183 W9000185 Woes gt W9000198 Fifth Wheel Instructions 319 Fifth Wheel There are three operating positions for the fifth wheel locking mechanism ASF fifth wheel is shown Locked This is the position that the fifth wheel will be in with a trailer hooked up In the locked position the operating rod is retracted and the safety latch will freely swing back and forth W9000180 Lockset This is the position the fifth wheel is in when uncoupling the trailer To achieve the lockset po
224. s Area Dual Wheels One Or Two Axles Check condition of wheels and rims Especially look for cracks missing lockrings bent or broken spacers studs clamps or lugs Check condition of tires properly in flated no serious cuts bulges tread wear or any signs of misalignment valve stems not touching wheels rims or brake drums valve caps in place and no objects stuck between the wheels Check that both tires are of same type for example not mixed radial and bias type and that their circumferences are matched Check wheel bearing and hub no obvi ous leaking on outside or inside wheel Suspension Check condition of springs leaf or air spring hangers shackles and U bolts no cracks breaks or shifting 38 Pre Trip Inspection and Daily Maintenance Brakes Condition of brake drums With brakes released look for a noticeable gap be tween lining and drum This check cannot be made if dust covers are in place Condition of brake hoses check for any chafing Check brake chamber mounting bolts and brackets Check slack adjusters and chamber push rod travel With brakes applied or released look for conspicuously dif ferent positions of the slack adjusters Check spring brakes Condition of Visible Components Transmission not leaking Drive shaft looks OK Exhaust system secure not leaking not touching wires fuel or air tubing Frame and cross members no bends cracks or breaks
225. s generator triggers and fills the bag with a non toxic gas within a few hundredths of a second During a colli sion after the bag has been filled gas flows out through two holes in the weave These holes are large enough to let the airbag col lapse slowly gently catching the driver In the event of a problem in the SRS sys tem a telltale shows on the graphic display in the instrument cluster This telltale to gether with other telltales in the cluster also light up when the engine is started The telltale should go out after approxi mately 10 seconds when the starting key has been turned to the drive position eo W3000982 If a problem develops in the system the AINFO telltale will come on together with the SRS telltale The vehicle should be taken to an autho rized Volvo Truck dealer immediately if the SRS telltale stays on or lights up when the vehicle is being driven 64 Additional Safety Features Warning Labels The label attached to the left hand sunvisor shows the year and month when a Volvo Truck dealer should be contacted for a specific inspection and for a possible re placement of the airbag This is done to guarantee the function of the airbag after the stated date Replace the label when re placing the airbag module Never attempt to make any adjustments to SRS compo nents yourself Steering shafts and steering wheel should not be removed adjusted or replaced with out following the pro
226. s no information available for how many times the fault code has been active only Active is shown the fault remains or Inactive the fault was there previously Numeric Text Time stamp Reset MID 128 PID 110 FMI 0 Active gt 1 oe The arrow in the lower right hand corner is shown if there is more than one fault code The up down buttons move the cursor and the next fault code is shown If the correct password has been entered resetting can be done in Reset all last in the list This resetting deletes only the fault codes for the chosen ECU If more than 20 fault codes messages are available for the chosen ECU the 21st message will be To see those messages that are not shown earlier messages must be reset password restricted see page 158 Graphic Display 141 Too many error Messages 142 Graphic Display Time stamp 1 To show the time when the fault code was set for the first and latest occasion respectively press SELECT when the particular fault code is presented does not apply to ABS brakes or SRS airbag The following menu is shown Select Time stamp and the following text message is shown The following is shown time stamp is presented as the number of hours the engine has been running Press Esc to return to the previous menu If the transfer should fail the follow ing message is shown Numeric Text Time stamp Reset Data transfer in progr
227. scending steep grades Each engine has its ideal operating ranges for power and economy Read the engine manufacturer s manual to find out the best ranges for each engine Always keep an eye on the tachometer during downhill runs Do not allow the engine to over speed Excessive engine over speed can result in serious engine damage e 40 pi L i P mph amp or r GEEAE Er TORS el Teal K W3003643 W3003639 Instruments and Controls H Speedometer and Odometer The speedometer is driven by the vehicle s electronic system Recalibration of the speedometer can be made to compensate for tire size changes or other changes in the vehicle driveline This is done by repro gramming the engine or transmission electronic controller Reprogramming can be performed by your authorized Volvo Truck dealer The odometer is a Liquid Crystal Display LCD mounted in the lower speedometer face The odometer registers up to 999 999 9 miles or km The internal elec tronics will make distance conversions between miles and km automatically To be able to read the current mileage without turning the ignition on press any graphic display control to activate the odometer and clock for approximately 30 seconds 83 W3003640 84 Instruments and Controls J Master Warning Telltale N DANGER The Master Warning Telltale and buzzer alerts of a dangerous situation A
228. sible damage Make sure that it works properly Check the buckle by inserting the latch and verifying proper operation Determine if the latch plate is worn or deformed Check the buckle and latch casing for cracks or breakage W8001404 58 Additional Safety Features The retractor web storage device is mounted on the B pillar just behind the door in the cab The retractor is the heart of the safety belt system and can be damaged if abused even unintentionally Check the retractor web storage device operation to ensure that it is not locked and that it spools out and retracts the webbing properly If tethers are being used to anchor the ioe safety belts to the floor make sure that they E are properly attached to the seat Tethers C AS must also be inspected for web wear and Zs ae ok proper tightness of mounting hardware ff W8001387 All hardware for safety belt mounting points should be evaluated for corrosion All attachment points of the system should be checked for tightness of mounting hardware Check the web in areas exposed to ultra violet rays from the sun or extreme dust or dirt If the original color of the web in these areas is extremely faded the physical strength of this web may have deteriorated If this condition exists replace the safety belt system Additional Safety Features 59 Important Facts About Safety Belts in Heavy Trucks The high mileage associated with heavy trucks the
229. sing the front axle for towing minimizes the possibility for damage to the vehicle body frame and sus pension NOTE When the drive shaft or axle shafts are reinstalled make sure the nuts are tight ened to the correct torques Also make sure the axle shafts are installed in the proper sides with the left shaft in the left side and the right shaft in the right side Emergency Information Caging Spring Brake Chambers The parking spring brake chambers may be released mechanically if there is no com pressed air available N DANGER Always start by chocking the wheels to prevent the vehicle from rolling Failure to do so can result in unexpected vehicle movement and serious personal injury or death can occur Remove the plastic plug in the front end of the chamber Remove the screw from the holder in the side of the brake chamber In sert the screw into the front hole and push in until it bottoms Screw into the cylinder so at least 4 to 6 threads have entered 339 W5000643 340 Emergency Information Install the washer and nut Tighten the nut This compresses the brake chamber spring and releases the parking brake N DANGER Do not attempt in any way to disassem ble or tamper with the spring brake chamber If the force stored on the spring is suddenly released it can cause serious personal injury or death W5000644 Service Information 341 Service Assistance and Manuals Your Volvo Tr
230. sition the operating rod is pulled out with a slight upward mo tion The operating rod shoulder will catch on the plate casting The safety latch is ro tated toward the rear of the fifth wheel W9000242 Open This is the position the fifth wheel is in after the trailer is uncoupled The jaw is open and the operating rod is now dropped down and can be freely moved around The safety latch is rotated toward the rear of the fifth wheel This is the position the fifth wheel must be in when being coupled to a trailer W9000203 320 Fifth Wheel Instructions Fifth Wheel Slider option The fifth wheel comes standard with an air operational slider To remain within legal weight limits this feature allows the driver to distribute the load easily on the axles The air operated slider takes the work out of adjusting the tractor for various trailer loads The fifth wheel portion is easily ad justed even with a fully loaded trailer connected Movement between the adjustable saddle plate and the stationary base plate rail can result in wear causing longitudinal latitu dinal and vertical slack Field repairs can be made to reduce this slack for additional service life W9000205 Fifth Wheel Instructions 321 Unlocking the Fifth Wheel Always check out the entire fifth wheel equipment before attempting to couple to a trailer ASF fifth wheel is shown e If not lubricated properly add grease to the top o
231. sits in the engine and turbocharger This causes excessive en gine wear and oil consumption Excessive smoke not only pollutes the atmosphere but can also cause shortened exhaust system life Engine Break In Engines used in the VN series are run on dynamometers before being shipped from the manufacturer In most applications the engine can be put to work immediately but the operator should be extra observant of the operating conditions shown on the gauges during the initial 100 hours or 3000 miles 5000 km A more frequent check of the engine com partment for fluid leaks fluid levels and fastener tightness is also recommended dur ing the initial period 257 258 Engine Start and Operation Engine Shut Down System DANGER Failure to take the necessary precautions when the AINFO or ASTOP telltales are on can ultimately result in automatic engine shut down and the loss of power steering Vehicle crash can occur Astor The engine shut down system will automat ically derate or stop the engine when one or more of the systems listed below reaches a critical stage T3008861 e High Coolant Temperature e Low Oil Pressure A N nro e Low Coolant Level T3008860 Derate and shut down functions may be ap plied differently or added to depending on the engine manufacturer See the engine op erator s manual for more information When the shut down is activated the telltales come on and the buzzer is
232. slow down al low the transmission to remain in gear with the throttle closed disengaging the clutch only when engine idling speed is reached When parking the vehicle place the transmission in neutral and set the parking brake before shutting down the engine When descending a long grade do not use the service brakes too long or too often The brakes may overheat and lose their effectiveness Before descending a steep grade the transmission should be shifted into a lower gear and the vehicle speed re duced Other speed retardation devices should also be used if available en gine brakes retarders or trailer hand control valves 277 278 Brakes Parking Brake Trailer Supply Valves Trucks Tractors have two air control valves on the instrument panel e Trailer Supply red octagonal knob e System Park yellow diamond knob The two air control valves are intercon nected and interacting The System Park valve supplies and controls the Trailer Air Supply valve The System Park valve knob yellow should be pushed in first after sufficient air pressure is built up apply foot brake to pre vent vehicle from rolling The Trailer Air Supply valve knob may then be pushed in The Trailer Air Supply valve knob and Sys tem Park valve knob will automatically pop out if the system pressure both front and rear circuits drops to 25 to 35 psi 170 to 240 kPa The tractor protection valve will then close the tractor sp
233. stracting the operator with a glaring light The door switch operates all door activated lights The switch is located in the rear part of the door frame a The switch has a shut off function that can be used if the door needs to be open and the lights should not be on To deactivate the lights grasp the stem of the switch with two fingers push it in and twist clockwise The stem stays in and the light is off _ When the switch stem is pushed in and re w3000970 leased either by hand or by the door it will return to the normal working position 204 Cab Interior and Sleeper Sleeper Section The sleeper section has individual bunk light fixtures for all types of sleeper cabs They are of the same type as the front overhead lights They are operated by the switch on the fixture There are overhead fluorescent lights in the VN 610 VN 660 and VN 770 The fluorescent overhead lights can be op erated from the sleeper panel switch For the VN 770 model there is also a switch for the overhead fluorescent light in the left hand switch cluster on the dash This switch can be reached from outside the cab door to enable the light to be turned on without having to climb into the cab W3002425 W3001351 W3002002 Cab Interior and Sleeper There is a separate fluorescent light over the table in the VN 770 and an incandes cent light over the table in the VN 660 There is a switch in the sleeper panel on
234. sword required see page 158 e Reset trip data Vehicle ID MENU Data log mode Vehicle ID 1 Select the menu Data log mode Vehi cle ID and the following text message Data transfer is shown ai in progress please wait 2 The fleet ID that is shown has been Fleet ID entered in the menu i Press Esc to return to the previous XXX one Chassis no XXX 3 If the transfer should fail the follow ing message is shown Operation failed Totals MENU Data log mode Totals 1 Select the menu Data log mode To tals The menus that show Totals can be scrolled to using the up down but tons NOTE If km and C has been selected the consumption is shown in liters Graphic Display 153 Total distance 406 7 mi Total fuel used 51 3 gal Total engine hours 7 3 h Total idle time 0 3 h 154 Graphic Display Total PTO hours 0 5 h Total engine revolutions 1 220 100 r 3 Tf the transfer should fail the follow ing message is shown Operation Cancel operation failed Press Esc in order to cancel the operation Graphic Display 155 Trip data Volvo engine only MENU Data log mode Trip data 1 Select the menu Data log mode Trip 2 The information below can be scrolled to using the up down buttons Trip distance 203 5 mi NOTE If Miles and F has been se Trip fuel lected the consumption is shown in US gallons Avg 28 1
235. t should be checked out by a qualified heater technician or contact the manufacturer 194 Heating and Air Conditioning A C Diagnostic Module Problem Codes The diagnostic module has two LED lights one green and one red which indicate if a system problem has been detected If a problem is detected a fault code or blink code is activated to identify the condition The blink codes listed on the label are Slow Green Normal Fast Green Low system voltage 1 Red Blink Loss of refrigerant w3002004 2 Red Blinks Overcharge blockage or fan failure 3 Red Blinks Open or shorted clutch or circuit 4 Red Blinks Open pressure switch or circuit N DANGER The air conditioning system is under pressure The possibility of an explosion is possible if serviced incorrectly A qualified technician should perform any service needed Failure to follow this may lead to an explosion causing severe injury or death Seats General Several different seats can be used in the vehicles If the seat installed in the vehicle is not explained in this section look for the seat manufacturer s manual in the Owner s Package On the driver s side there is a standard seat and an upgrade that includes adjustable air cushions for lumbar and thigh back sup port arm rests and a frame cover The top of the line is a Volvo comfort seat W8002743 National Standard Seat The passenger side can have the same type of seat as o
236. t TOO am HIGH This warning will come on when E TOO HIGH the oil temperature has been 285 F 140 C 73008831 o or above for over 30 seconds 285 F N DANGER Failure to take necessary action when the ASTOP telltale is on can ultimately STOP result in automatic engine shutdown and loss of power steering assist Vehicle 73008861 crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked 130 Graphic Display Acknowledge Information and Stop Messages By pressing Esc the display with the fault message is reset and the graphic display re turns to the same status as before the error occurred An acknowledged fault message is shown as a symbol on the right in the graphic display window All types of fault messages can be acknowledged Acknowl edged but active messages are shown again when the ignition key is turned to the start position T3008852 Yellow INFO telltale The text message A INFO yellow TNFPO telltale and the symbol can be acknowledged using Esc This warning is acknowledged until the next time the ig nition key is turned to the start position T3008860 Exceptions The message can be shown again if the fault is de activated and then becomes active again Example If the engine oil temperature be comes too high a message is activated automatically The driver acknowledges this message using Esc If the temperature then
237. t and the jaw is closed the pin must be visually inspected from the mons rear Use a flashlight if necessary Make sure the trailer bed is resting on the top surface of the fifth wheel plate and that there is no visible gap between the fifth wheel and the trailer bed plate N DANGER Make sure trailer is properly connected W9000240 before moving vehicle Trailer separa tion accident and injury or death may occur if trailer is not properly connected Fifth Wheel Instructions Make sure the operating rod is fully re tracted the safety latch is positioned above the handle and the latch swings freely If the fifth wheel is equipped with a manual secondary lock check to see that it is prop 327 erly engaged NOTE If you cannot get a proper cou pling repeat this procedure Do not use any fifth wheel which fails to operate properly Check the kingpin to fifth wheel clearance by moving the tractor backward and for ward with the trailer brakes set If the clearance appears excessive more than 1 8 in 3 mm or if the jaw does not lock the fifth wheel should be inspected by a qualified technician before proceeding Wind up the trailer landing gear trailer support to its fully retracted position Fold down or remove the crank handle and place it in the crank handle holder Check the air brake lines and the trailer light cord connections Remove the wheel chocks from
238. t of damage to the vehicle is no measure of how well the SRS system works Additional Safety Features 67 Can the airbag be deployed acci dentally The complete SRS system is constructed so that the airbag only inflates in particular collision conditions The SRS system has its own diagnostic unit which continuously monitors the functioning of the system Make a habit of checking the SRS system telltale light when starting and driving the vehicle Heart of the Volvo safety system The three point anchored safety belt is the heart of the Volvo safety system The belt should be worn at all times The SRS system is intended as a supplement to the three point anchored safety belt 68 Additional Safety Features Safety Equipment Safety triangles and fire extinguishers are available as optional equipment The fire extinguisher should be located by the base of the driver seat between the seat and the door Depending on the cab style the safety triangles are located in different places in the cab W1000071 Day Cab The warning triangles are stored in a box that is strapped to the back wall Sleeper Cab The warning triangles are stored in a box that is strapped to the inner wall of the right side luggage compartment W1000139 Additional Safety Features 69 VORAD Collision Warning System The Eaton VORAD computerized Collision Warning System constantly monitor vehi cles ahead with a front end mounted radar and
239. t on the rolling resistance Accessories As a rule accessories such as roof rack ad vertising signs bug screens exposed air horns etc have a negative effect on fuel consumption Service and Maintenance A modern heavy duty vehicle requires reg ular and preventive maintenance to ensure that all its components function as they should Use the recommended preventive maintenance PM program that Volvo Trucks North America Inc has developed for the vehicles This ensures optimal en ergy efficiency from all components that are important to fuel consumption Tires If the tire pressure is too low the rolling resistance increases and thereby increases the fuel consumption The overall economy is also affected as tire wear increases considerably Brakes Dragging brakes increase fuel consumption They should be checked regularly It is im portant that the release action of the air valves is fast and that the moving parts of the wheel brakes are checked for good ad justment and operation 239 240 Fuel Economy Driving Axles An axle out of alignment will increase rolling resistance Regularly check the front wheel alignment and axles on both the trac tor and trailer semi trailer If they are correct there will be less rolling resistance and therefore lower fuel consumption A good sign of an axle or wheel out of alignment is uneven tire wear Check the tires often Engine Faulty or incorrectly adjusted
240. tart to flash 7 operate Only complete hours or 0 59 minutes can be set The letter h ap 7 Press the up button to set the number of hour the parking heater should pears after the indicated hour digit Accept the indicated time by pressing SET The display will show ON meaning that the heater is ready to be started If the heater is not to be started press one of the up or down buttons and a VA 7 OFF is now displayed To alternate between ON and OFF press the up or down button Accept that the heater is to be ON or OFF by pressing SET The heater will start and run for the set time if ON was chosen or stand by if OFF was cho sen At the same time as the SET button is pressed the display returns to the clock function If the time setting was not completed the display returns to the clock function 30 seconds after the last button was pressed 192 Heating and Air Conditioning Parking Heater Delayed Start bated a K Symbol for delayed start of parking heater The symbol flashes until the function is changed To select the function to start the parking heater use the MODE button to switch between functions until the delayed start symbol appears Press the SET button The hour digits start to flash Set the hour digits to the time when it is desired that the heater should start The up button increases the time delay and the down button decreases the time delay Accept the delay hours by pressing the SET
241. te within the economic speed range at normal driving speed This range is defined as where the engine makes the best use of the energy content of the diesel fuel A poorly selected rear axle ratio which re sults in the engine speed being constantly above the optimum speed will increase fuel consumption Superstructure and Air Fairings The frontal area of the vehicle and trailer superstructure is what pushes the air aside The smoother the transition between the aerodynamic front and cab to the trailer superstructure the better the airflow With better airflow the engine has to pro duce less power to push the air to the side especially at higher speeds There are partial and full air fairing pack ages available that should cover most vehicle specifications and applications With flatbed trailers using tarpaulins to cover the load make sure the cover is tied down well and presents a smooth surface Tires Heavy duty treaded tires increase rolling resistance considerably For long haul choose a smoother ribbed type tire Choose a lugged type tire only when the added traction in mud and snow is needed The number of wheels axles has a direct effect on the rolling resistance and thereby the fuel consumption For volume and or low weight transports the use of a 4x2 in stead of a 6x4 should be considered Fuel Economy Driving Gross Vehicle Weight The gross vehicle weight of a vehicle com bination has a large impac
242. ted by pulling the turn signal lever toward the steering wheel The high beam will stay on W3000903 until the lever is released W2002694 To change between high and low beam pull the lever all the way toward the steer ing wheel When a slight clicking sound is heard release the lever EEI NOTE When switching from high to low beam for oncoming traffic release the lever a as soon as the beam change is made Hold a A ing the lever up makes the headlight flash function stay engaged W3001303 98 Instruments and Controls Windshield Wiper Washer The wiper washer functions are operated by the same switch The wipers have a normal and a fast speed which are activated by moving the lever down one or two posi tions To let the wipers engage for one or two passes lightly depress the lever until the wipers start and hold it there The wipers return to the parking position when the lever is released The interval wiper function is engaged by moving the lever up The normal pro grammed speed is one pass every 10 seconds To shorten the interval time move the lever to normal wipe position and then to the interval position again when the next wiper pass is desired In this way the inter val can be programmed between 1 to 10 seconds between each pass To operate the windshield washer pull the lever toward the steering wheel If washer fluid needs to be added use a commercially reputable washer fluid that has good cle
243. the trailer wheels N DANGER Make sure trailer is properly connected before moving vehicle Trailer separa tion accident and injury or death may occur if trailer is not properly connected W9000180 328 Fifth Wheel Instructions Trailer Uncoupling Procedures For Tractors With Air Ride Suspension Set the system park brake on the tractor Set the trailer brakes by pulling out the trailer air supply knob Chock the trailer wheels Use two chocks one on the front and one on the rear of the wheel on both sides of the trailer W9000263 Wind down the landing gear until it touches the ground and then give it a few extra turns in low gear Do not raise the trailer off of the fifth wheel Fold down or remove the crank handle and place it in the crank handle holder NOTE In poor ground conditions it may be necessary to provide a stable base for the landing gear Fifth Wheel Instructions 329 Disconnect the light cord and air brake lines Use the dummy air couplings to keep foreign material from entering the brake lines Unlock the fifth wheel lt NOTE If the operating rod is too difficult to pull back the tractor up slightly to re A w an X lieve any kingpin load against the fifth wheel jaw 9 g mala a ZZ W9000275 Release the tractor park brakes and pull the tractor away from the kingpin about 12 in 300 mm and STOP Do not allow the fifth wheel to leave the
244. time For certain symbols a measurement value is also shown NOTE In the event of a warning for low air pressure no message is shown on the graphic display the LED in the gauge lights up instead together with the master warning telltale see page 84 Important When the AINEFO telltale lights up the specified fault must be checked at the next stop Stop message DANGER Failure to take necessary action when the ASTOP telltale is on can ultimately result in automatic engine shutdown and loss of power steering assist Vehicle crash resulting in personal injury or death can occur Bring the vehicle to a safe stop where the problem can be checked In the event of serious faults the red ASTOP telltale lights up and a warning buzzer sounds if the engine is running In addition to the telltale a symbol or text is shown on the graphic display at the same time For certain symbols a measurement value is also shown NOTE In the event of a warning for low oil pressure or coolant temperature in the engine no text is shown on the display the LED in the respective gauge lights up instead Graphic Display ZAM nro T3008860 T3008861 171 172 Graphic Display Information symbols The yellow INFO telltale lights up and a symbol is shown on the graphic display Airbag For airbag SRS sys tem information see page 63 Overheating in struments The symbol will be shown when the tem pera
245. top part of the lid in and the lid will fold out To close press the lid in until the latch closes There are also two cupholders molded into the engine cover W8001875 230 Cab Interior and Sleeper Curtains Curtains are available for all the sleeper cabs to ensure privacy and to darken the cabin from outside light Various configura tions are available Curtains can cover the whole windshield area or go across the sleeper opening i W8001877 When the curtains are not in use they are stored out of the way and held in place with velcro straps W8001880 Covers for the VN 660 are to be stored in a rolled up position in the opening behind the cabinet The covers for the VN 770 side windows are stored behind the backrest cushions All covers are put on with snap buttons that are on the cover and window rim W8001911 Communication and Entertainment 231 Antennas Multiband Antenna There are antennas mounted on the top of the mirror brackets for wideband reception They receive or send signals for radio CB and telephone Each antenna carries multi ple wire windings that work together with mirror bracket devices to cover the needs of many uses If the antenna is damaged replace it only with a multiband type antenna A regular antenna does not have the wiring necessary to give good reception for all uses W3001997 TV Antenna For the VN 770 the TV antenna is stan dard equipment It is
246. topped with the engine running for more than a few minutes e Adjust the heating or cooling system to force outside air into the cab Do this by setting the fan to medium or high speed and with the controls set in any position except for recirculation of air inside of the cab e Keep the exhaust pipe area clear to help reduce the buildup of exhaust gas under the vehicle Heating and Air Conditioning Cab Air Filters Air going into the cab passes a filter lo cated on the right front side of the cab Remove the filter and clean with an air gun no more than 20 psi pressure after 40 000 miles 64 000 km in dusty conditions as often as every 10 000 miles 16 000 km Make sure the air stream is directed from the inside out The filter should not be cleaned and reused more than once Replace with a new filter after maximum 70 000 miles 110 000 km or earlier if driving in dusty conditions A clogged filter decreases the efficiency of the air conditioning system If the vehicle is equipped with a sleeper heater A C there is a filter for the recircu lating air This is located behind the passenger seat on the bunk support The fil ter should be checked and cleaned after 40 000 miles 64 000 km in dusty condi tions as often as every 10 000 miles 16 000 km Clean as the cab air filter Replace filter after 100 000 miles 160 000 km To inspect or to change the filter open lug gage storage lid and pull out filter
247. ture in the instrument cluster ex ceeds 198 F 92 C The instrument lighting becomes weaker and the gauges show the minimum reading When the cab tempera ture cools the instrument cluster func tions will gradually be restored Level washer fluid The washer fluid sym bol lights when the washer fluid is low T3008842 OFO T3008840 T3008838 Warning trans mission oil temperature If the temperature of the transmission oil be comes too high an information message is shown automatically with the text HIGH It comes on when the transmission oil is 250 F 120 C or over for more than 10 min utes or 210 F 100 C or over for more than 30 minutes The tem perature is displayed along with the symbol Yt F T3008831 Warning volt meter If the battery voltage becomes too high the voltmeter s value is _ shown automatically as well as the text TOO PARRES HIGH This warning is triggered at 17 V The voltage is displayed along with the symbol Warning tem perature engine oil If the engine oil tem perature becomes too high a stop message is shown automatically with the text TOO HIGH The engine out put is reduced The temperature limit which activates this warning varies for different en gines This limit is set in the engine ECU Air filter clogged The symbol is shown when the air filter sen sor is restricted aF T3008830 T3008843 Gr
248. u Because of your special preferences needs and circumstances you may want to add extra mirrors and or other visibility en hancement devices If so you should contact an authorized Volvo Truck dealer to obtain those parts which best fit your own personal needs and preferences All items within the cab must be secured before the vehicle is set in motion This includes but is not limited to drinks clothes books televisions etc In the event of a collision loose items could fly around inside the cab This could cause personal injury 4 General Information Operating In Bobtail Mode Tractors are equipped with a bobtail air brake proportioning valve which automati cally redistributes the braking force between front and rear axles when not hooked up to a semitrailer bobtail operation When operating in bobtail mode the rear brake chambers receive reduced or propor tional brake air pressure When the tractor is towing a trailer the rear brake chambers will receive full normal brake pressure NOTE When operating bobtail be certain that glad hands trailer air hoses electrical cable and connectors are properly stowed and secure Do not allow them to rub or chafe on other components When operating bobtail the brake system on the vehicle reduces the possi bility of rear wheel brake lockup except on full pedal application When bobtail ing be certain that adequate pedal pressure is applied There is no n
249. uck dealer is trained and Delivery equipped to perform expert service on your Assurance Volvo vehicle Your dealer has direct access to Volvo Trucks North America Inc for technical help parts or service information Personal There is also a direct number to Volvo Ac Assurance tion Service VAS staffed 24 hours a day S if you are in need of assistance The num Uptime ber to the Customer Support Center is Assurance 1 800 528 6586 or 800 52 VOLVO Also on the internet www vas volvo com VAS can offer Price Assurance If you have a breakdown VAS can arrange for load forwarding or equipment rental Trained staff for handling any vehicle problems VAS will locate the near est service provider and guarantee payment so you can get on the road as soon as possible VAS audits service and parts billing to ensure guaranteed labor rates and preferred parts pricing for Volvo compo nents 342 Service Information To order a single Service Manual or a Ser vice Manual Set for your vehicle you should contact your authorized Volvo Truck dealer or fax a request to the Volvo Truck North America Inc publications warehouse Fax 336 668 3625 They will help you locate the manual s you need To be able to handle the order correctly you must give the model year and VIN For VIN location see page 16 Current prices for a Service Manual Set are 350 00 for vehicles with a Volvo engine and 300 00 for vehicl
250. unds flasher indica tor reminder and caution are tested for 10 seconds The caution sound is connected to the red STOP telltale 3 Esc cancels the test and the menu Buzzer test is shown again 149 150 Graphic Display Part number MENU System diagnostics Part number A list of the vehicle s electronic control units ECUs is shown in the menu Part number Each ECU is identified by a MID number Message IDentifier ABS Brakes MID 136 Instrument cluster center module MID 140 Display MID 234 SRS Airbag MID 232 Vehicle ECU MID 144 Engine MID 128 The up down buttons are used to move the cursor in the list SELECT confirms the selection of an ECU In the meantime the display shows the text The following text is presented SW The software part number Data transfer in progress please wait MID 128 SW ID 03163028P01 The up down buttons are used to move the cursor in the list HW ECU part number If there is a communication error the following is shown No data this ex ample shows HW ID but same text applies to SW ID except that HW is replaced by SW Graphic Display 151 MID 128 HW ID VOLVO08192949P06 MID 128 HW ID No data 152 Graphic Display Main Menu Data Log Mode Volvo Engine Only Menu Data log mode has 4 sub menus where 3 are not protected by passwords and 1 is protected by a password e Vehicle ID e Totals e Trip data Pas
251. up and forward e Place the left hand on the steering wheel and the right hand on the top of the gear lever e Move the right foot out to the middle of the floor e Lift the upper body supported by the hands on the steering wheel and the gear lever and step out from the seat area W8002037 Vehicle Access 27 Folding Gear Lever option When moving from the driver seat to the sleeper section follow this procedure e Make sure the parking brakes are set e To release the gear lever pull the lever toward the seat and press on the knob downward in a straight line W4001388 e Twist the lever counterclockwise while holding pressure on the knob When releasing the pressure the springloaded lever will be pushed up out of the locked position W4001389 e Lift and fold the gear lever straight back parallel with the seat It will come to rest in the folded position NOTE If the lever is not folded straight back it may not be able to travel the full distance W4001390 28 Vehicle Access e If equipped with an adjustable steering column move the steering wheel up and forward e Place the left hand on the steering wheel and the right hand on the top of the dash e Move the right foot out to the middle of the floor e Lift the upper body supported by the hands on the steering wheel and the dash and step out from the seat area N DANGER When locking the gear lever in place again follow the
252. ust temperature to vary For example high exhaust gas temperature is the result of prolonged engine lugging or overfueling If the pyrometer reading shows that exhaust temperature exceeds normal reduce fuel to the engine until exhaust temperature is re duced Shift to a lower gear if the engine is overloaded W3003632 Instruments and Controls 75 B Engine Coolant Temperature The gauge indicates engine coolant temper ature Normal operating temperature 170 glo reading is 165 to 205 F 75 to 95 C for ISO 230 the VOLVO engine The temperature under 4 e normal driving conditions must be below gt the red sector The temperature range for the coolant will vary depending on the type of engine load grade ambient air tempera ture and operating conditions If the E temperature remains below or exceeds the mu oon normal temperature range the cooling sys tem should be checked for problems by your Volvo Truck dealer W3003769 is dependent on the engine manufacturer electronic program Together with the gauge light the red ASTOP telltale will come on and the buzzer will also sound The engine is at risk and the engine con troller may react by derating the engine power Stop at the first safe place where the AN STOP problem can be checked The LED light in the lower right corner of the gauge lights up solid when coolant tem perature is excessive The temperature limit Erom eN OS i a W3003614
253. wer at approximately the same road speed For shifting instructions see the transmission manufacturer s Opera tor s Manual Always start moving the load in a gear low enough so that the engine can be acceler ated to the governed speed Then shift to the next gear as the engine decelerates For loaded vehicles do not skip a gear or lug the engine while getting up to cruising speed For empty or light loads it is per missible to skip gears When operating on a level highway or at cruising speed hold the engine speed at ap proximately 75 to 85 percent of governed speed 1400 to 1600 r min for large dis placement engines to achieve power and economical fuel consumption Engine Start and Operation The operator should understand the operat ing characteristics of the engine the vehicle is equipped with Modern diesel engines have maximum torques at much lower en gine speeds than in the past As such these engines are designed to perform satisfacto rily at a lower speed New transmissions with wide ratio steps between gears de mand the use of these engines Excessive exhaust smoke may be due to the type of fuel used a restricted air cleaner a malfunctioning fuel system or the way the vehicle is operated Shift gears and increase or decrease the engine speed as necessary to obtain the engine speed transmission gear combination which will prevent smok ing Excessive smoke indicates wasted fuel which creates carbon depo
254. when the switch is pressed Acceleration Momentary acceleration such as for over taking another vehicle does not interrupt cruise control operation After overtaking release accelerator and let the vehicle slow to cruise control speed The previously set speed will then be maintained without hav ing to set the switch to RESUME Engine Start and Operation 267 Fuel Tank Cap s N DANGER Do not remove the fuel tank cap near an open flame Diesel fuel vapors are com bustible and can cause an explosion or fire resulting in severe personal injury or death Some fuel tank caps have a pressure and a thermal relief function built into the cap These functions are designed to avoid fuel spills in the event of an accident The pres sure relief function of the safety venting system has a crack pressure high enough to retain fuel in the tank regardless of the ori entation of the vehicle 5 to 8 psi The thermal relief feature is large enough to limit tank pressure to a safe level even when the remaining fuel is boiling in the tank but not so large as to dump fuel un necessarily The thermal relief should respond as much as possible to fuel tem perature rather than flame temperature These features are also available on the op tional lockable fuel tank cap w2003144 Only replace the cap with a cap contain ing the same features described above Unnecessary fuel spills leading to in creased fire hazard may
255. will light up and the master warning indicator and the buzzer will simultaneously come on If the air pressure is allowed to drop below 30 to 40 psi 205 to 275 kPa in both systems the parking brakes will automatically engage to stop the vehicle Refer to page 273 for ues more information about the brakes Master Warning Indicator DANGER Failure to observe these precautions can result in the loss of braking performance and personal injury or death can occur as a result of a vehicle crash 92 Instruments and Controls R Warning Telltales Right Section IEA 1 2 3 4 5 6 1 Transmission Temperature this page Check Transmission this page Traction Control System page 93 Wait to Start Not used Automatic Neutral page 94 A ua gt Q N Water in Fuel Not used Transmission Temperature Telltale The Transmission Temperature Telltale is for the Allison WTEC II transmission The amber warning signal lights up and a buzzer sounds when the transmission tem perature is too high W3004305 Check Transmission Telltale The Check Transmission Telltale is for the Allison WTEC III transmission The red warning signal lights up to indicate a trans mission problem Depending on the severity of the problem shifts may be restricted es i W3004416 Instruments and Controls Traction Control System Telltale The amber telltale will blink only when the Traction Control System TCS mud snow
256. witch 245 Clutch pedal switch 246 Brake pedal switch 1 247 Brake pedal switch 2 248 Proprietary data link 249 SAE J1922 data link 250 SAE J1708 data link 251 Power supply 252 Calibration module 253 Calibration memory 254 Controller 1 Engine Description SID code Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 Engine position sensor 1 2 6 22 Timing sensor N Nn Ext engine protection sig Transm Description SID code C1 solenoid valve C2 solenoid valve C3 solenoid valve C4 solenoid valve C5 solenoid valve C6 solenoid valve 1 5 27 29 Lockup clutch PSI sw Forward range PSI sw Neutral range PSI sw Reverse range PSI sw Vehicle Description Naviga tion SID code Dead reckoning LORAN receiver Global positioning system GPS Integrated navigation unit Graphic Display 145 Brake Description FMI Description SID code code 1 ABS snsr axle 1 L 0 Data valid but high 2 1 Data valid but low 3 2 Data erratic 4 3 Voltage shorted high 5 ABS snsr axle 3 L 4 Voltage shorted low 6 ABS snsr axle 3 R 5 Current low or open C 7 ABS valve axle 1 L 6 Current high or short C 7 Mech syst no respons 8 Abnormal freq or PW ABS valve axle 2 R 9 Abnormal update rate ABS valve axle 3 L 10 Abnormal change rate ABS valve axle 3 R 11 Failure unknown ABS rtrdr ctrl relay 12
257. ws and vents are closed At all times make sure the cowl fresh air intake is free from snow ice leaves etc NOTE The air conditioning system is con tinuously monitored for correct function The monitor module has a read out for fault codes See page 194 for more information W8001116 W8001003 W8001004 N DANGER Do not attempt to drive with the wind shield covered by mist fog or frost The visibility is reduced which could lead to an accident causing severe personal in jury or death Heating and Air Conditioning 175 Climate Unit Main Control Panel Fan Speed Control The fan has four speeds and can also be shut off With the fan control in the O posi tion air still flows out of the dash vents if the vehicle is moving at highway speeds and if the Fresh Air Control is set for out side air intake If the Fresh Air Control is W8001466 set for full recirculation the fan has to be on for air to flow out the dash vents If equipped with air conditioning the fan is not controlled by the system to change fan speed with changing temperatures Adjust the fan speed to the desired air flow Fan speed must be selected to meet either heating or cooling needs For the heater only and manual air conditioning variants of the climate system settings of tempera ture and air flow must be adjusted as often as necessary to accommodate changing temperatures outside and inside the cab The ATC system is desi
258. y signs of misalignment valve stem not touching wheel rim or brake drum valve cap in place Check wheel bearing and hub no ob vious leaking on outside or inside wheel Verify correct oil level in hub Pre Trip Inspection and Daily Maintenance a eee oo gt N w Step 3 Right Side Of Cab Area cont Right Front Suspension Check condition of spring spring hangers shackles U bolts no cracks breaks or shifting Shock absorber condition Right Front Brake Condition of brake drum With brakes released look for a noticeable gap be tween lining and drum This check cannot be made if dust covers are in place Condition of brake air hose check for any chafing Check brake chamber mounting bolts and bracket Check slack adjuster and chamber pushrod travel With brakes applied or released look for conspicuously dif ferent positions of the slack adjusters Condition of Front Axle and Steering Sys tem Right Side No loose worn bent damaged or missing parts 35 W0001230 Under Hood Right Side Check condition of coolant and heater hoses Check condition of fan drive belts Check engine and surrounding areas for coolant oil and fuel leaks Check fuel separator sight glass and drain if necessary Check for leaks Check wiring harnesses for signs of damage Check air filter with brackets and hoses for loose connections or dam age Check filter gauge if mounted on the filte

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