PV776-20 003739

Quick-Reference GuideVN, VHD VERSION2

December 2004

This booklet replaces“Quick-Reference Guide

VN, VHD VERSION2” datedJanuary 2003, Publication No.

PV776-20 182094

ForewordThis book is intended primarily for technicians, but also may behelpful to others who need technical information about the vehicleor related components.

Information has been compressed to accommodate the sizerestrictions of this format. Therefore, always refer to the appropriatetechnical service information for the most complete and current data.

The following levels of observations, cautions and warnings are usedin this Service Documentation:

Danger: Indicates an unsafe practice where serious personal injury ordeath could occur.

Warning: Indicates an unsafe practice where personal injury or severedamage to the product could occur.

Caution: Indicates an unsafe practice where damage to the productcould occur.

Note: Indicates a procedure, practice, or condition that must be followedin order to have the vehicle or component function in the mannerintended.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-20 003739

© 2004 Volvo Trucks North America, Inc., Greensboro, NC USA

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

Contents0. General ............................................... 1

Tightening Torques, General ................. 1Data Link Communication .................... 3Vehicle Identification ........................... 14

1. Service and Maintenance ................ 16Oil Change Volumes .............................. 16

2. Engine ............................................... 19Specifications ......................................... 19

General ................................................ 19Engine .................................................. 21Valves .................................................. 23Timing Gears and Camshaft ................ 28Lubrication and Oil Systems ............... 37Fuel System ......................................... 39Intake and Exhaust System .................. 40Cooling System ................................... 47Engine Control System ........................ 50Tightening Torques and Patterns ......... 55

3. Electrical System and Instruments 74Specifications ......................................... 74

Fuse and Relay Locations .................... 74Tightening Torques .............................. 75Group 35 — Light Control Module .... 77

5. Brakes ............................................... 80Specifications ......................................... 80

Drum Brake ......................................... 80Compressor .......................................... 82Air Drier .............................................. 86Brake Valves ........................................ 89

6. Suspension and Steering................. 97Specifications ......................................... 97

Wheel Alignment ................................ 97Steering ................................................ 98

7. Chassis, Springs, Damping, andWheels ................................................. 101Specifications ....................................... 101

Suspension ......................................... 101Wheels ............................................... 106

8. Body, Cab, and Interior Trim ....... 108Specifications ....................................... 108

Cab Designations ............................... 108Seats ................................................... 109Climate Control Unit ......................... 110

0. General 1

Tightening Torques, GeneralStrength Classes 4.8, 5.8

4.8 5.8

Thread Nm (ft-lb) Thread Nm (ft-lb)

M3 0.6 ± 0.1 (0.4) M5 3.5 ± 0.5 (2.5)

M4 1.5 ± 0.5 (1.1) M6 6 ± 1 (4.4 ± 0.7)

M5 3 ± 0.5 (2.2) M8 15 ± 2.5 (11 ± 1.8)

M6 5 ± 0.8 (3.6) M10 30 ± 4.5 (22 ± 3.3)

M8 12 ± 2 (8.8 ± 1.4) M12 50 ± 8 (37 ± 6)

M10 24 ± 4 (18 ± 3)

Strength Classes 8.8, 10.9Level Application Action after choice

Low Joints with low friction (μ≈ 0.1)

None

Average General application (μ ≈0.15)

None

High Joints with high friction (μ≈ 0.2) E.g. weld nuts of height1d.1, untreated steel surfaces, mm

Test

1 d = thread diameter

Strength class 8.8, Nm (ft-lb)Thread

Low Average High

M5 5 ± 0.8 (3.7) 6 ± 1 (4.4 ± 0.7) 7 ± 1.2 (5.2 ± 1)

M6 8 ± 1.2 (6 ± 1) 10 ± 1.5 (7 ± 1) 12 ± 2 (9 ± 1.4)

M7 15 ± 2.5 (11 ± 1.8) 17 ± 3 (13 ± 2) 20 ± 3 (15 ± 2)

M8 20 ± 3 (15 ± 2) 24 ± 4 (18 ± 3) 28 ± 5 (21 ± 3)

M10 40 ± 6 (30 ± 4) 48 ± 8 (35 ± 6) 56 ± 10 (41 ± 7)

M12 70 ± 12 (52 ± 9) 85 ± 15 (63 ± 11) 100 ± 15 (74 ± 11)

M14 115 ± 20 (85 ± 15) 140 ± 25 (103 ± 18) 160 ± 25 (118 ± 18)

M16 185 ± 30 (137 ± 22) 220 ± 35 (162 ± 26) 255 ± 40 (188 ± 30)

M18 250 ± 40 (185 ± 30) 290 ± 45 (214 ± 33) 340 ± 50 (251 ± 37)

2 0. General


Low Average High

M20 360 ± 55 (266 ± 41) 430 ± 70 (317 ± 52) 500 ± 80 (369 ± 59)

M22 490 ± 80 (362 ± 59) 580 ± 90 (428 ± 66) 680 ± 100 (502 ± 74)

M24 620 ± 100 (458 ± 74) 740 ± 120 (546 ± 89) 860 ± 140 (635 ± 103)


Low Average High

M5 6 ± 0.1 (4.4) 7.5 ± 1.2 (5.5 ± 1) 9 ± 1.5 (6.6 ± 1)

M6 10 ± 1.5 (7.3 ± 1) 12 ± 2 (9 ± 1.4) 15 ± 2.5 (11 ± 2)

M7 15 ± 2.5 (11 ± 2) 22 ± 3 (16 ± 2) 24 ± 4 (18 ± 3)

M8 25 ± 4 (18 ± 3) 30 ± 5 (22 ± 3.7) 35 ± 6 (26 ± 4)

M10 50 ± 8 (37 ± 6) 60 ± 10 (44 ± 7) 70 ± 12 (52 ± 9)

M12 85 ± 15 (63 ± 11) 105 ± 20 (77 ± 15) 125 ± 20 (92 ± 15)

M14 150 ± 25 (111 ± 18) 175 ± 30 (129 ± 22) 200 ± 30 (148 ± 22)

M16 230 ± 35 (170 ± 26) 275 ± 45 (203 ± 33) 320 ± 50 (236 ± 37)

M18 310 ± 50 (229 ± 37) 360 ± 55 (266 ± 41) 410 ± 60 (303 ± 44)

M20 450 ± 70 (332 ± 52) 540 ± 90 (399 ± 66) 630 ± 100 (465 ± 74)

M22 610 ± 100 (450 ± 74) 730 ± 120 (539 ± 89) 850 ± 140 (627 ± 103)

M24 750 ± 120 (554 ± 89) 900 ± 140 (664 ± 103) 1050 ± 160 (775 ± 118)

0. General 3

Data Link CommunicationCommunication between the different Electronic ControlUnits (ECUs) takes place via the two data links: theJ1939 control data link and the J1587/1708 informationdata link.

The diagram below shows how the control units, thediagnostic connector, and the instrument cluster areconnected in principle.

The instrument cluster, the Engine ECU (EECU),vehicle ECU (VECU), Light Control Module (LCM)andthe diagnostic connectorare always included inthe system. The system may include other control units,depending on the vehicle type and optional equipment.

W3005654

4 0. General

Fault CodesMID Message Identification Description

(identification of ECU)

PID Parameter Identification Description(identification of parameter (value))

PPID Proprietary Parameter IdentificationDescription (Volvo-uniqueidentification of parameter (value))

SID Subsystem Identification Description(identification of component)

PSID Proprietary Subsystem IdentificationDescription (Volvo-uniqueidentification of component)

FMI Failure Mode Identifier(identification of fault type)

0. General 5

MIDsMID 128 Engine Electronic Control

Unit (EECU)MID 130 Transmission ECUMID 136 Anti-lock Brake (ABS)

control unitMID 140 Instrument clusterMID 142 Satellite CommunicationsMID 144 Vehicle control unit

(VECU)MID 146 Climate control unitMID 216 Lighting control module

(LCM)MID 232 Airbag (SRS), control

unitMID 249 Bodybuilder module

(BBM)

MID 250 Steering wheel module(SWM)

J1939–1 Main network SAE J1939J1939–2 Section of SAE J1939

connected to the vehiclecontrol unit

J1939–3 Section of SAE J1939connected to theinstrument cluster

J1939–4 Section of SAE J1939connected to thebodybuilder control unit

6 0. General

Common Fault Codes

MID 128Fault code diagnostics, refer to MID 128fault codes, IMPACT or ID DVD: Info type“Diagnostics” group 2841

FaultCode

Component/Function

PID 26 Fan speed %

PID 27 EGR position sensor 1

PID 45 Preheater status

PID 84 Vehicle speed

PID 85 Cruise control status

PID 91 Accelerator pedal position

PID 94 Fuel supply pressure

PID 97 Water in fuel indicator

PID 98 Engine oil level

PID 100 Engine oil pressure

PID 102 Intake manifold pressure

PID 105 Intake manifold temperature

PID 108 Atmospheric pressure

PID 110 Engine coolant temperature

PID 111 Engine coolant level

PID 153 Crankcase pressure

PID 158 Battery voltage

PID 171 Ambient temperature

PID 172 Air temperature, intake

PID 175 Engine oil temperature

PID 228 Road speed sensor calibration

PID 245 Total Vehicle Distance

PID 362 EGR position sensor 2

FaultCode

Component/Function

PPID 86 Engine brake torque percent

PPID 119 High coolant temperature

PPID 122 VCB compression brake status

PPID 124 EPG 1

SID 1-6 1/2/3/4/5/6 Unit injectors

SID 18 Drain Valve, Water Separator

SID 21 Engine position, cam sensor

SID 22 Engine speed, flywheel sensor

SID 33 Fan control

SID 70 Preheater element 1

SID 71 Preheater element 2

SID 78 Fuel supply pump

SID 146 EGR valve 1

SID 211 5 volt DC supply

SID 230 Idle validation switch

SID 231 SAE J1939 Control link

SID 232 5 Volt DC supply

SID 240 Program memory

SID 253 Data set memory EEPROM

SID 254 Engine ECU (EMS2)

SID 266 EGR valve 2

SID 281 EGR reed valve diagnose

SID 282 EGR cooler efficiency

PSID 201 SAE J1939 Data link interuption

0. General 7

MID 136

FaultCode

Component/Function

SID 1 ABS sensor, axle 1 L

SID 2 ABS sensor, axle 1 R





SID 7 ABS valve, axle 1 L

SID 8 ABS valve, axle 1 R


FaultCode

Component/Function




SID 13 ABS retarder control relay

SID 14 ABS relay, diagonal 1

SID 15 ABS relay, diagonal 2

SID 18 ABS, ASR valve, diff 1

SID 19 ABS, ASR valve, diff 2

MID 140

Faultcode

Component / function

PID 77 Forward rear axle temperature

PID 78 Rear rear axle temperature

PID 96 Fuel level

PID 116 Application air pressure

PID 117 Air brake pressure, front

PID 118 Air brake pressure, rear

PID 158 Battery voltage

PID 171 Ambient temperature

PID 177 Transmission oil temperature

PID 178 Air suspension pressure, front

PID 179 Air suspension pressure, rear

SID 231 SAE J1939 Data Link

Faultcode



SID 250 SAE J1587/J1708 data link

SID 253 Calibration memory, EEPROM

PSID 7 Internal reference resistance

PSID 200 Open-circuit, J1939 Data Link, EECU

PSID 201 Open-circuit, J1939 Data Link, VECU

PSID 204 Open-circuit, J1939 Data Link, ABS

unit

PSID 210 Open-circuit J1939 Data Link, Lighting

control module

PSID 232 SAE J1939-3 Data Link

8 0. General

MID 142

FaultCode

Component/Function

PID 155 Output 1-4

PID 155 Input 1-4

PID 154 Input 5-8

SID 240 Memory flash/RAM

SID 250 J1708/1587 Data Link

SID 253 Memory ROM

PSID 3 Sending message failure

FaultCode

Component/Function

PSID 4 GPS module/interface

PSID 5 DSP module/interface

PSID 6 ORBCOMM satellite module/interface

PSID 8 J1708/1587 road speed

PSID 161 J1708/1587 VIN missing

PSID 162 VIN mismatch

MID 144

Faultcode

Component

PID 84 Vehicle speed

PID 91 Accelerator pedal, percentage position

PID 150 PTO output (Volvo engine only)

PID 152 VECU, number of resets

PID 191 Output shaft speed

PPID 61 Retarder switches (Volvo engine only)

PPID 69 Buffered idle validation switch (Volvo

engine only)

PPID 70 Pedal switches, supply

PPID 71 Cruise control and engine brake, switch

supply

PPID 72 Accelerator pedal and engine brake,

sensors supply

PPID 74 VECU power supply

SID 230 Idle validation switch 1

Faultcode

Component

SID 231 SAE J1939 Control Data Link


SID 243 Cruise control, set switch

SID 250 Information link SAE J1708

SID 253 Calibration memory EEPROM

PSID 4 Engine brake stalk lever (Cummins

6–level engine brake only)

PSID 200 Engine timeout

PSID 202 Instrument timeout

PSID 204 ABS/EBS timeout

PSID 210 LCM timeout

PSID 214 BBM timeout (VOLVO engine only,

vehicles equipped with BBM)

0. General 9

MID 146

Faultcode


PID 170 Cab, temperature sensor

PID 171 Temperature sensor, outer temperature

SID 2 Temperature sensor, evaporator

SID 5 Stepper Motor, Fresh Air and

Recirculation

SID 6 Stepper motor, air distribution

SID 9 Stepper motor, air mixture Electronic

Climate Control (ECC), heat control

Manual Climate Control, (MCC, BAS)

SID 11 Magnetic clutch, air conditioning (A/C)

compressor

SID 12 Solenoid valve, water control

SID 13 Temperature sensor, heat exchanger

Faultcode


SID 14 Circulation fan, temperature sensor, cab

SID 15 Fan connection, engine

SID 16 Stepper motor, phase 1




SID 22 Pressure sensor, refrigerant, high

pressure side

SID 232 5 volt supply to the sensor

SID 250 SAE J1708 data link

PID 170 Cab, temperature sensor

10 0. General

MID 216

Faultcode



SID 250 SAE J1587/1708 Information link


SID 254 Control unit

PSID 1 High beam, left

PSID 2 Low beam, left

PSID 3 High beam, right

PSID 4 Low beam, right

PSID 5 Fog lights

PSID 7 Driving lights

PSID 8 Reverse lights

PSID 10 Brake light, left

PSID 11 Brake light, right

PSID 12 Brake lights, trailer

PSID 13 Direction indicator, left front

PSID 14 Direction indicator, right front

PSID 17 Direction indicator trailer, left side

PSID 18 Direction indicator trailer, right side

PSID 19 Relay, intermittent wiper

PSID 20 Dashboard dimming

PSID 27 Snow plow lights

PSID 28 Hazard sound indication

PSID 29 Indicator light, warning light

PSID 30 Light switch, warning light

PSID 33 Stalk switch high/low beam

Faultcode


PSID 34 Power supply 1






PSID 40 Power supply, ignition key in driving

position

PSID 41 Stalk switch direction indicator

PSID 42 Rheostat, instrument lighting

PSID 45 Side repeater, right

PSID 46 Side repeater, left

PSID 48 Park and licence plate lights, tractor

rear

PSID 49 Tractor roof marker/clearance lamps

PSID 50 Tractor front park lights

PSID 51 Trailer park lights

PSID 52 Allison retarder indicator LED

PSID 53 Marker (ICC) trailer

PSID 54 Marker interrupt

PSID 55 Headlamp interrupt

PSID 57 Back of cab lights

PSID 200 SAE J1939 Open-circuit, data link,

engine control unit

PSID 201 SAE J1939 Open-circuit, data link,

vehicle control unit

0. General 11

MID 232

FaultCode

Component/Function

SID 1 Detonation circuit, airbag module


SID 253 Calibration memory

FaultCode

Component/Function

SID 254 Defective unit or component

PSID 1 Wrong VIN response

PSID 2 No VIN response

MID 249

FaultCode

Component/Function

PID 29 Extra throttle control, percentage

position

SID 230 Idle switch



PSID 200 SAE J1939 open circuit, Data Link,

engine ECU

FaultCode

Component/Function


vehicle ECU


instrument cluster ECU


automatic transmission ECU

MID 250

FaultCode

Component/Function


SID 251 Power supply, control unit steering

functions (SWM)

SID 254 Control unit steering wheel module

(SWM)

PSID 3 Arrow left

PSID 4 Arrow right

PSID 5 Volume (+)

FaultCode

Component/Function

PSID 6 Volume (-)

PSID 9 Headlamp interrupt

PSID 10 Marker interrupt

PSID 17 Power supply, switch steering wheel

buttons

PSID 18 Data link, switch steering wheel buttons

12 0. General

FMI Table

FMI Display Text SAE Standard Text

0 “Value too high” Correct value, but above normal working range

1 “Value too low” Correct value, but below normal working range

2 “Faulty data” Intermittent or faulty data.

3 “Electrical fault” Abnormally high voltage or short circuit to higher voltage

4 “Electrical fault” Abnormally low voltage or short circuit to lower voltage

5 “Electrical fault” Abnormally low current or open circuit

6 “Electrical fault” Abnormally high current or short circuit to earth (ground)

7 “Mechanical faults” Faulty response from mechanical system.

8 “Mechanical or electricalfault”

Abnormal frequency

9 “Communication fault” Abnormal updating rate

10 “Mechanical or electricalfault”

Abnormally large variations.

11 “Unknown fault” Unidentifiable fault

12 “Component fault” Faulty unit or component, or loss of communication

13 “Faulty calibration” Calibration values outside limits

14 “Unknown fault” Special instructions.

15 “Unknown fault” Reserved for future use.

0. General 13

Diagnostic Connector

W3005648

Fig. 1: Diagnostic Connector

9–pin Diagnostic Connector

CavityPosition

Circuit Description

A 0Z (B-)

B 402 (B+)

C 406C (CAN_H, yellow)

D 407C (CAN_L, green)

E not used

F 400G (SAE A, 1708)

G 401G (SAE B, 1708)

H not used

J 196DR (Ignition)

The diagnostic connector is a roundconnector located in the driver’s side kickpanel. The diagnostic connector connects toboth the J1939 and J1587/1708 data link andgives the system a way to communicate withan external PC or diagnostic tool.

With a PC or diagnostic tool connected, faultcodes can be read from all the control units.This is important in fault tracing to carryout basic checks of all the vital parts of thevehicle’s electronics.

Most programming can also be done via thediagnostic connector.

14 0. General

Vehicle Identification

LabelsIt is extremely important that the correct vehicle modeland Vehicle Identification Number (VIN) are givenwhenever replacement parts or service literature areordered. Using these numbers, as well as giving themajor component model and serial numbers, will preventdelay and errors in obtaining the correct material.

Vehicle Identification Label

W8003115

The full 17-digit VIN is shown on theVehicle Identification label located in thedoor opening on the driver’s side. The VINcontains the following information:

• Manufacturing location• Engine type• Check sum figure• Assembly factory• Type of cab• Brakes / axle combination• Model year• Chassis number

Certification LabelThree labels are located in the rear insideframe of the driver side door frame. Theselabels should not be removed.

On the top part of the door frame is theCertification label showing the axle and loadratings for the vehicle as it is built. DO NOTexceed these ratings by overloading.

Noise Emission Control LabelThe Noise Emission Control label is locatedat the bottom of the three labels on therear inside frame of the driver side door. Itis the Owner’s responsibility to maintainthe vehicle so that it conforms to EPAregulations.

0. General 15

Chassis Number

W0001995

The 8-digit chassis number is embossedinto the frame rail at two locations: thebottom flange right-hand side, and the topflange left-hand side of the frame rail. Thesenumbers are set 1065 mm (42 in.) back fromthe front edge of the frame rail.

Engine

W2003921

The Volvo D12D engine serial number islocated on the rear, left side of the cylinderblock.

The serial number can also be found on thecertification label on the valve cover.

Rear Axle

W4002560

The axle model and serial number is locatedon the front left side of the forward driveaxle and the front right side of the rear driveaxle. It is also located on the front right sideof the single axle.

Transmission The transmission label may include the typeof transmission, part number, serial number,and service category. Location of the labeldepends on transmission manufacturer.

16 1. Service and Maintenance

Oil Change Volumes

For the most current information on oil capacitiesand oil change intervals, refer to Service Bulletin175-60, “Oil and Filter Change Intervals for VOLVOComponents.”

For the most current list of approved oils for specificapplications, refer to Service Bulletin 175-61,“Approved Oils List, VOLVO Components.”

Engine

Approximate oil change capacity

Vehicle Engine Normal oilchange (incl.filter)

Dry capacityMax. to Min.on dipstick

VN D12D33 L(35 qts)

37 L(39 qts)

8 L(8.5 qts)

VHD D12D38 L(40 qts)

42 L(44 qts)

6 L(6.5 qts)

Power Take-off

Model Oil change volume, approx.

flywheel-mounted 5.0 L (5.3 qt)

1. Service and Maintenance 17

Rear Axle

Approx. oil change volume, L (qt)Model

Final drive Each hub Total

RSS1344B 17.5 L (18.5 qt) 17.5 L (18.5 qt)

RS1356SV Leaf springs 8.5 L (9 qt) 8.5 L (9 qt)

RS1356SV Air springs 9 L (9.5 qt) 9 L (9.5 qt)

RS1352HV1 19 L (20.1 qt) 1.5 L (1.6 qt) 22 L (23.2 qt)

RS1352HV Leaf springs 20 L (21.1 qt) 3 L (3.2 qt) 26 L (27.5 qt)

RS1352HV Air springs 16 L (16.9 qt) 3 L (3.2 qt) 22 L (23.2 qt)

RS1365HV 22 L (23.2 qt) 3 L (3.2 qt) 28 L (29.6 qt)

RS1370HV1 19 L (20.1 qt) 1.5 L (1.6 qt) 22 L (23.2 qt)

RS1370HV Leaf springs 20 L (21.1 qt) 3 L (3.2 qt) 26 L (27.5 qt)

RS1370HV Air springs 16 L (16.9 qt) 3 L (3.2 qt) 22 L (23.2 qt)

CTEV87 (front axle) Leaf springs 20 L (21.1 qt) 20 L (21.1 qt)

CTEV87 (rear axle) Leaf springs 9 L (9.5 qt) 9 L (9.5 qt)

CTEV87 (front axle) Air springs 16 L (16.9 qt) 16 L (16.9 qt)

CTEV87 (rear axle) Air springs 7.5 L (7.9 qt) 7.5 L (7.9 qt)

RT2610HV (front axle) Leaf springs 23 L (24.3 qt) 3 L (3.2 qt) 30 L (31.2 qt)

RT2610HV (rear axle) Leaf springs 19 L (20.1 qt) 3 L (3.2 qt) 26 L (27.5 qt)

RT2610HV (front axle) Air springs 23 L (24.3 qt) 3 L (3.2 qt) 29 L (30.6 qt)

RT2610HV (rear axle) Air springs 19 L (20.1 qt) 3 L (3.2 qt) 25 L (26.4 qt)

RT3210HV (front axle)1 22.5 L (23.8 qt) 1.5 L (1.6 qt) 25.5 L (26.9 qt)

RT3210HV (front axle) Leaf springs 22.5 L (23.8 qt) 3 L (3.2 qt) 28 L (29.6 qt)

RT3210HV (rear axle)1 18.5 L (19.5 qt) 1.5 L (1.6 qt) 21.5 L (22.7 qt)

RT3210HV(rear axle) Leaf springs 18.5 L (19.5 qt) 3 L (3.2 qt) 24 L (25.3 qt)

RTH2610B (front axle) Leaf springs 23 L (24.3 qt) 3 L (3.2 qt) 30 L (31.7 qt)

RTH2610B (rear axle) Leaf springs 19 L (20.1 qt) 3 L (3.2 qt) 26 L (27.5 qt)

1 The oil volume is only 1.5 liter for hub reduction housings with part numbers 1524851 or 1524852. Thesemarkings can be seen on the hub reduction housings.

18 1. Service and Maintenance

Driving Front Axle


FS0910HZ 11.5 L (12.1 qt)Please note that the hub change volumes are notincluded in these figures. The change volume foreach hub is 1.5 liter (1.6 qt).

Transfer Case


VT2501TB 5.5 L (5.8 qt)

Hydraulic Retarder


RET-TH 5.4 ± 0.1 L (5.7 ± 0.1 qt)

2. Engine 19

SpecificationsGeneral

Power Output 1 Torque 2

D12D 365 272 kW (365 hp) 1800 Nm (1328 ft-lb)

D12D 395 295 kW (395 hp) 2000 Nm (1476 ft-lb)

D12D 425 317 kW (425 hp) 2000 Nm (1476 ft-lb)

D12D 435 325 kW (435 hp) 2100 Nm (1549 ft-lb)

D12D 465 347 kW (465 hp) 2237 Nm (1650 ft-lb)1 Max power output at 30.0 rps (1800 rpm). Net power according to ISO 1585. Smoke requirements met

according to ECE reg 24 Federal Register and Swedish Authorities.2 Max torque at 20.0 rps (1200 rpm). Net torque according to ISO 1585. Smoke requirements met according to

ECE reg 24 Federal Register and Swedish Authorities.

20 2. Engine

General Engine Specifications

Number of cylinders 6

Cylinder diameter 131 mm (5.16 in.)

Stroke 150 mm (5.91 in.)

Displacement12.1 L (738.39 cubicin)

Firing sequence 1-5-3-6-2-4

Compression ratio 17.3:1

Compression test using VCADS Pro, deviation from peak value100% max 20%

Engine speed during compression test, minimum 16.7 r/s (100 rpm)

Low idle8.3 - 10.8 r/s (550 -650 rpm)

High idle 38.4 r/s (2300 rpm)

Max. full load revs 35.0 r/s (2100 rpm)

Weight, engine with flywheel, flywheel casing and turbocharger,without starter motor (dry) 1175 kg (2585 lb)

Max length 1350 mm (53.2 in.)

Max width 768 mm (30.2 in.)

Max height 1152 mm (45.4 in.)

2. Engine 21

EngineCylinder

Cylinder Head

Type 6 cylinder

Length 1078 mm (42.4 in.)

Width 397 mm (15.6 in.)

Height 135 mm (5.3 in.)

Maximum unevenness (bottom face) 0.1 mm (0.004 in.)

Cylinder Head Bolts

Number/cylinder head 38

Thread size M16

Length 200 mm (7.87 in.)

Cylinder Block

Length 1052 mm (41.42 in.)

Height, lower block face - crankshaft center 120 mm (4.72 in.)

Cylinder Liner

Type Wet, replaceable

Height, total 273 mm (10.75 in.)

Sealing surface height above block face 0.15 - 0.21 mm (0.006 - 0.008 in.)

Number of sealing rings per cylinder liner 1 + 3

22 2. Engine

Piston

Type steel

Height above cylinder block face 0.15 - 0.65 mm (0.006 - 0.026 in.)

Diameter, combustion chamber 89 mm (3.50 in.)

Depth, combustion chamber 18.6 mm (0.73 in.)

Number of ring grooves 3

Front marking arrow turned forward

Wrist pin diameter 55 mm (2.17 in.)

Piston Rings

Compression rings Specification Wear tolerance

Number 2 -

Piston ring clearance in grooves:

lower compression ring 0.09 - 0.13 mm (0.0035 -0.0051 in.)

-

Piston ring gap measured in ring opening:

upper compression ring 0.4 - 0.65 mm (0.016 -0.026 in.)

< 1.0 mm (0.039 in.)

lower compression ring 1.1 - 1.3 mm (0.043 -0.051 in.)

< 1.6 mm\ (0.063 in.)

Oil scraper ring Specification Wear tolerance

Number 1 -

Width, including spring4.32 mm(0.170 in.) -

Piston ring clearance in groove0.05 - 0.10 mm(0.0019 - 0.0039 in.) -

Piston ring gap measured in ringopening

0.35 - 0.65 mm(0.0137 - 0.0260 in.)

< 1.0 mm(0.039 in.)

2. Engine 23

ValvesValve disc, diameter:

Intake 40 mm (1.6 in.)

Exhaust 40 mm (1.6 in.)

Valve stem, diameter:

Intake 8 mm (0.315 in.)

Exhaust 8 mm (0.315 in.)

Valve seat angle (A):

Intake 29.5

Exhaust 44.5

Seat angle in cylinder head (B):

Intake 30

Exhaust 45

T2019432

Clearance between valve head and cylinder head face:

Specification Wear tolerance

Intake 0.9 - 1.4 mm(0.035 - 0.055 in.)

< 1.5 mm(0.059 in.)

Exhaust 1.2 - 1.7 mm(0.047 - 0.067 in.)

< 1.8 mm(0.071 in.)

Note: Valves must be replaced when replacing valve seats.

24 2. Engine

Valve clearance, cold engine, setting value:

Intake 0.2 mm (0.008 in.)

Exhaust 0.5 mm (0.019 in.)

Exhaust, VEB 1.6 mm (0.063 in.)

Valve clearance, cold engine, control values:

Intake 0.15 - 0.25 mm (0.006 - 0.009 in.)

Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in.)

Exhaust, VEB 1.55 - 1.65 mm (0.061 - 0.065 in.)

Valve Seats

Outer diameter (A)

Standard:

Intake 43.1 mm (1.697 in.)


Oversize:

Intake 43.3 mm (1.705 in.)


Height (B):

Intake 7.3 mm (0.287 in.)


2. Engine 25

Valve Seat Location

Diameter (C) standard:

Intake 43.0 mm (1.693 in.)


Diameter (C) oversize:

Intake 43.2 mm (1.701 in.)


Depth (D) :

Intake 11.2 mm (0.441 in.)


Seat bottom radius (R):

Intake, maximum 0.8 mm (0.032 in.)

Exhaust, maximum 0.8 mm (0.032 in.)

26 2. Engine

Valve Guides


Length:

Intake 83.4 mm(3.283 in.) -

Exhaust 83.4 mm(3.283 in.) -

Inner diameter:

Intake 8 mm(0.315 in.) -

Exhaust 8 mm(0.315 in.) -

Height above the cylinder head spring plate:

Intake 26.5 ± 0.4 mm(1.043 ± 0.016 in.) -

Exhaust 26.5 ± 0.4 mm(1.043 ± 0.016 in.) -

Clearance, valve stem - guide:1

Intake < 0.2 mm (0.008in.)

Exhaust < 0.2 mm (0.008in.)

1 Measurements are calculated for the method described in Service Information, group 21.

2. Engine 27

Valve Springs

Intake (left-hand coil)

Length (unloaded) 73 - 74 mm (2.87 - 2.91 in.)

590 Nm (435 ft-lb) load 58 mm (2.28 in.)

1150 Nm (850 ft-lb) load 45 mm (1.77 in.)

Butt length max 40 mm (1.57 in.)

Exhaust

Outer valve spring (left-hand coil):


590 Nm (435 ft-lb) load 58 mm (2.28 in.)

1150 (850 ft-lb) Nm load 45 mm (1.77 in.)


Inner valve spring (right-hand coil):


330 Nm (244 ft-lb) load 54 mm (2.13 in.)

630 Nm (465 ft-lb) load 41 mm (1.61 in.)


Rocker Arms

Bearing play, maximum < 0.1 mm (0.0039 in.)

Rocker arm roller, play, maximum < 0.1 mm (0.0039 in.)

28 2. Engine

Timing Gears and CamshaftTiming Gear Wheels

Backlash 0.05 - 0.17 mm(0.002 - 0.007 in.)

Shaft journal for intermediate gear, diameter 99.99 ± 0.01 mm(3.937 ± 0.0004 in.)

Bushing for intermediate gear, diameter 100.04 ± 0.01 mm(3.939 ± 0.0004 in.)

Diametrical clearance for intermediate gear max 0.07 mm(0.003 in.)

Axial clearance for intermediate gear max 0.17 mm(0.007 in.)

2. Engine 29

C2001718

Number of teeth:

1 Drive gear, crankshaft 38

2 Intermediate gear, coolant pump 83

3 Drive gear, coolant pump 27

4 Drive gear, air compressor 29

5 Drive gear, camshaft 76

6 Intermediate gear (adjustable) 97

7 Drive gear, power steering pump 23

8 Drive gear, (pulley and fuel pump) 27

9 Intermediate gear 71

10 Drive gear, hydraulic pump 39

11 Drive gear, lubrication oil pump 23

12 Intermediate gear, lubrication oil pump 44

30 2. Engine

Camshaft

Checking camshaft settings, cold engine and valve clearance, cylinder 1 = 0.The intake valve for cylinder 1 for flywheel position 6� after TDC must be open 1.6 ± 0.3 mm (0.064 ± 0.012 in.).

When checking, the timing gears must be turned in the correct direction (clockwise viewed from front) to eliminate any

backlash.


Drive Gear -

Number of bearings 7 -

Diameter bearing journals, standard 69.97-70.00 mm(2.754 - 2.760 in.) -

Note: Use only to check values, not for machining.

Diameter bearing journals, undersize: -

0.25 69.72 - 69.78 mm(2.746 - 2.747 in.)

-

0.50 69.47 - 69.53 mm(2.735 - 2.737 in.)

-

0.75 69.22 - 69.28 mm(2.725 - 2.728 in.)

-

Max axial play 0.35 mm (0.014 in.)

Max permitted out-of-roundness (with new bearings) 0.05 mm (0.0019in.)

Bearing, permitted wear diametrical 0.05 mm (0.0019in.)

Valve lift:

Intake 13.1 mm (0.52 in.) -

Exhaust (VEB) 13.1 mm (0.52 in.) -

Exhaust (EPG) 12.0 mm (0.47 in.) -

Decompression and charge profiles(VEB)

1.1 mm (0.043 in.) -

Permitted wear for the complete cam profile < 0.1 mm (0.0039in.)

Unit injector, stroke 17 mm (0.67 in.) -

2. Engine 31

Camshaft bearing thickness, standard 1.92 mm (0.075 in.)

Oversize:

0.25 2.04 mm (0.079 in.)

0.50 2.17 mm (0.087 in.)

0.75 2.29 mm (0.091 in.)

Crankshaft

Length 1203 mm (47.36 in.)

Crankshaft axial clearance1 0.10 - 0.40 mm (0.0039 - 0.0158 in.)

Main bearing radial clearance1 0.046-0117mm (0.0018-0.0046 in.)

Out-of-round, main bearing and connecting rodbearing pins, maximum 0.08 mm (0.0031 in.)

Taper on main bearing and connecting rod bearingpins, maximum 0.05 mm (0.0020 in.)

Run-out of the center bearing, maximum 0.15 mm (0.0059 in.)1 Measurements assume lubricated component.

32 2. Engine

Main Bearing Journals

(Use only for check values, not for machining.)

Diameter(ø) standard 108.0 mm (4.25 in.)

Undersize:

0.25 mm (0.01 in.) 107.73 - 107.75 mm (4.2413 - 4.2421 in.)

0.50 mm (0.02 in.) 107.48 - 107.50 mm (4.2315 - 4.2323 in.)

0.75 mm (0.03 in.) 107.23 - 107.25 mm (4.2216 - 4.2224 in.)

1.00 mm (0.04 in.) 106.98 - 107.0 mm (4.2118 - 4.2125 in.)

1.25 mm (0.05 in.) 106.73 - 106.75 mm (4.2020 - 4.2028 in.)

Surface finish, main bearing journal Ra 0.25

Surface finish, radius Ra 0.4

Width, thrust bearing journals (A), standard 47.0 mm (1.850 in.)

Oversize:

0.2 mm (0.008 in.), axial bearing 0.1 mm(0.004 in.) 47.175 - 47.225 mm (1.8573 - 1.8593 in.)



Fillet radius (R) 3.75 - 4.00 mm (0.148 - 0.157 in.)

2. Engine 33

Main Bearing Shells

Outer diameter (C) 113.05 mm (4.445 in.)

Thickness (D), standard 2.29 mm (0.098 in.)

Oversize:

0.25 mm (0.01 in.) 2.6 — 2.7 mm (0.102 — 0.106 in.)

0.50 mm (0.02 in.) 2.7 — 2.8 mm (0.106 — 1.110 in.)

0.75 mm (0.03 in.) 2.8 — 2.9 mm (0.110 — 0.114 in.)

1.00 mm (0.04 in.) 22.9 — 3.0 mm (0.114 — 0.118 in.)

1.25 mm (0.05 in.) 3.1 — 3.2 mm (0.122 — 0.126 in.)

Thrust Washers (Axial Bearings)

Width (B) standard 3.1 — 3.2 mm (0.122 — 0.126 in.)

Oversize:

0.1 mm 3.2 — 3.3 mm (0.126 — 0.130 in.)

0.2 mm 3.3 — 3.4 mm (0.130 — 0.134 in.)

0.3 mm 3.4 — 3.5 mm (0.134 — 0.138 in.)

34 2. Engine

Connecting Rods

T2012874

T2019085

“FRONT” on the shaft is turnedforward. Connecting rod andcap are marked as a pair with athree-figure serial number.

Length center - center(E) 260 mm (10.236 in.)

Connecting rod bushing internal diameter(G) 55 mm (2.165 in.)

Axial clearance, connecting rod - crankshaft, maximum1: 0.25 mm (0.0059 in.)

Connecting rod bearing, radial clearance, maximum1: 0.10 mm (0.0039 in.)

Out-of-true, max deviation on measuring length of100 mm (330 ft) 0.06 mm (0.0024 in.)

Torsion, max deviation on measuring length of 100 mm(330 ft) 0.15 mm (0.0059 in.)

1 Measurements are with lubrication.

2. Engine 35

Connecting Rod Bearing Pins

(Only for check values, not machining)Diameter (ø) standard 92.0 mm (3.62 in.)

Undersize:

0.25 mm (0.01 in.) 91.73 - 91.75 mm (3.611 - 3.612 in.)

0.50 mm (0.02 in.) 91.48 - 91.50 mm (3.601 - 3.602 in.)

0.75 mm (0.03 in.) 91.23 - 91.25 mm (3.592 - 3.593 in.)

1.00 mm (0.04 in.) 90.98 - 91.00 mm (3.582 - 3.583 in.)

1.25 mm (0.05 in.) 90.73 - 90.75 mm (3.572 - 3.573 in.)

Surface finish, connecting rod bearing journal Ra 0.25

Surface finish, radius Ra 0.4

Width (A) 56.9 - 57.0 mm (2.240 - 2.244 in.)

Fillet radius (R) 3.75 - 4.00 mm (0.148 - 0.157 in.)

36 2. Engine

Connecting Rod Bearing Shells

Outer diameter (B) 96.85 mm (3.813 in.)

Thickness (C), standard 2.39 — 2.40 mm (0.0941 — 0.094 in.)

Oversize:

0.25 mm (0.01 in.) 2.51 — 2.52 mm (0.0988 — 0.0992 in.)

0.50 mm (0.02 in.) 2.64 — 2.65 mm (0.1039 — 0.1043 in.)

0.75 mm (0.03 in.) 2.76 — 2.77 mm (0.1087 — 0.1090 in.)

1.00 mm (0.04 in.) 2.89 — 2.90 mm (0.1138 — 0.1141 in.)

1.25 mm (0.05 in.) 3.01 — 3.02 mm (0.1185 — 0.1188 in.)

Diameter, bearing shell bearing seat (D) 96.84 — 96.85 mm (3.8126 — 3.8129 in.)

Flywheel

Axial run-out (manual gearbox) measurement radius 150 mm(5.91 in.), maximum 0.20 mm (0.008 in.)

Number of teeth on starter motor gear ring 153

Sensor groove in flywheel 3 x 18

Flywheel Housing, Installed

Permitted axial runout for mating surface against clutch housing,maximum 0.20 mm (0.008 in.)

Permitted axial runout for location against clutch housing,maximum 0.25 mm (0.010 in.)

2. Engine 37

Lubrication and Oil SystemsOil Pressure

Operating speed (above 1100 rpm) 300-550 kPa (45 - 80 psi)

Idle speed, minimum 150 kPa (22 psi)

Oil Pressure, Rocker Arm Shaft

Non-activated VEB 100 kPa (15 psi)

Activated VEB min. 200 kPa (min. 30 psi)

Oil Temperature

Warm engine (running); coolant temperature 75 - 95C(167 - 203 F) 65 - 105 C (149 - 221 F)1

1 Up to 125�C (257�F) at high engine load

Oil Pump

Type Gear driven

Number of teeth:

Drive gear 23

Intermediate gear 44

Diameter:

Hub, intermediate gear 69.99 ± 0.01 mm (2.7555 ± 0.0004 in.)

Bushing, intermediate gear 70.04 ± 0.02 mm (2.7575 ± 0.0008 in.)

Axial clearance:

Drive gear, pump 0.11 mm (0.0043 in.)

Intermediate gear 0.10 mm (0.0039 in.)

Backlash 0.05 - 0.17 mm (0.0020 - 0.0067 in.)

Distance, drive gear — oil housing bracket 1.0 - 2.4 mm (0.0394 - 0.9449 in.)

38 2. Engine

Oil Filter

Number

Full-flow filter (is tightened 1/2 - 3/4 turn after contact) 2

Fine filter (is tightened 3/4 - 1 turn after contact) 1

Oil Valves

T2012843

1. Safety valve

Marking Yellow

2. Control valve, oil cooler (bypass valve)

(A) Marking 124

3, 5. Overflow valve, oil filter

Spring, free length 69 mm (2.72 in.)

With a load of 13 - 15 Nm 40 mm (1.57 in.)

4. Piston cooling valve

Marking Orange

6. Reduction valve

Marking Blue

2. Engine 39

Fuel SystemFuel Pump

Fuel pressure at:

600 rpm > 100 kPa (15 psi)

1400 rpm > 300 kPa (45 psi)

full load > 300 kPa (45 psi)

Overflow Valve

Opening pressure 360 - 420 kPa (53.6 - 62.5 psi)

Unit Injector

T2012878

Tighten the adjustment screw to zero clearance on the camshaft, then turn anadditional 3 - 4 flats (180 — 240�).

Preload setting, 3 - 4 flats (seeillustration) ...............................................

0.75 ± 0.1 mm (0.0295 ± 0.0039 in.)

Cylinder Balancing

Cylinder balancing, VCADS

Compensation, maximum ± 80%

40 2. Engine

Intake and Exhaust SystemTurbocharger

Axial clearance turbine rotor shaft, maximum 0.1 mm (0.0039 in.)

2. Engine 41

Minimum Charge Air Pressure at 100% Engine Load

Minimum @ 100%engine load

Pins EA22 (signal) &EA11 (sensor ground)1

Response Values2

D12D365:

1200 rpm 125 kPa (18.1 psi) 2.57 V 3.5 - 4.5 sec

1400 rpm 176 kPa (25.5 psi) 3.12 V 3.5 - 4.5 sec

1600 rpm 183 kPa (26.5 psi) 3.21 V 3.5 - 4.5 sec

1800 rpm 187 kPa (27.1 psi) 3.25 V 3.5 - 4.5 sec

D12D395:

1200 rpm 140 kPa (20.3 psi) 2.73 V 4.5 - 5.5 sec

1400 rpm 180 kPa (26.1 psi) 3.18 V 3.5 - 4.5 sec

1600 rpm 187 kPa (27.1 psi) 3.26 V 3.5 - 4.5 sec

1800 rpm 193 kPa (28 psi) 3.32 V 3.5 - 4.5 sec

D12D425:

1200 rpm 145 kPa (21 psi) 2.88 V 4.5 - 5.5 sec

1400 rpm 185 kPa (26.8 psi) 3.23 V 3.5 - 4.5 sec

1600 rpm 193 kPa (28 psi) 3.32 V 3.5 - 4.5 sec

1800 rpm 199 kPa (28.9 psi) 3.39 V 3.5 - 4.5 sec

D12D435:

1200 rpm 153 kPa (22.2 psi) 2.88 V 4.5 - 5.5 sec

1400 rpm 190 kPa (27.5 psi) 3.29 V 4 - 5 sec

1600 rpm 205 Kpa (29.7 psi) 3.46 V 3.5 - 4.5 sec

1800 rpm 206 kpa (29.9 psi) 3.47 V 3.5 - 4.5 sec

D12D465:

1200 rpm 175 kPa (25.3 psi) 3.12 V 4 - 5 sec

1400 rpm 206 kPa (29.9 psi) 3.47 V 3.5 - 4.5 sec

1600 rpm 224 Kpa (32.5 psi) 3.67 V 3.5 - 4.5 sec

1800 rpm 226 Kpa (32.8 psi) 3.69 V 3.5 - 4.5 sec

1Test run with normal diesel fuel (type 2) and below 1500 m (4500 ft.) altitude.2Response times from 0 kPa (0 psi) charge air pressure to 90% of max charge air pressure.

42 2. Engine

Charge Air Temperature Sensor

Cold engine (off) Ambient temperature

Warm engine (running, vehicle standing still); coolanttemperature 75 - 95 C (167 - 203 F)

10 - 30 C (50 - 86 F) aboveambient temperature

Exhaust Pressure Governor (EPG)

T2013094

EPG travel (A), minimum 29 mm (1.14 in.)

2. Engine 43

Heat Retention Function

Air pressure for exhaust pressure governor(EPG)

155 ± 8 kPa (23 ± 2 psi)

Heat retention activated:

Coolant temperature (minimum) < 70 — 80 C/ —4 (158 – 176 F /— 2 )

Engine load < approx. 50%1

Accelerator pedal at rest (released)

Heat retention deactivated:

Coolant temperature > 70 C (158 F)

Engine load > approx. 50%

Accelerator pedal off idle (depressed)1 Engine load could be more or less depending on engine speed. Check should be made with engine at idle speed.

44 2. Engine

EPG Activation for Idle EGR

Air pressure for exhaust pressure governor(EPG)

approx. 100 kPa (14.5 psi)

Activation:

Coolant temperature > 65 C (> 149 F)

Clutch pedal at rest (released)

Accelerator pedal at rest (released)

Engine speed idle

Ambient temperature > 4 C ( > 25 F)

EGR temperature > 98 C ( > 208 F) 1

1 Idle EGR is active when all conditions listed are met. After the first 3 minutes of idle time, the EMS readsthe EGR temperature. If below 98�C (208�F), idle EGR is not active. If above value, it remains active.Check parameter AZN in MID 128 (Engine ECU).

2. Engine 45

Engine BrakeEPG Inlet Pressure

Note: Checks should be made with oiltemperature greater than 55C (131 F)

T0008637

Braking force in %1

Pressure of EPG in kPa (psi)Exhaust brakeonly

100% (high) Cruise mode

Engine brake,switch position 1

750 kPa (109 psi) 50 - 750 kPa (7 - 109 psi)

1 2–way switch can give 100% (high) EPG only

T0008058

Brake force in %1

Pressure of EPG in kPa (psi)VEB

50% (low) 100% (high) Cruise mode2

EPG VCB

VEB Switchposition 1

750 kPa(109 psi)

– 50 — 750 kPa(7 — 109 psi)

On Off

VEB switchposition 2

750 kPa(109 psi)

750 kPa(109 psi)

50 — 750 kPa(7 — 109 psi)

On On

1 3–way switch can give 50% (low) or 100% (high) EPG and VCB2 Cruise control overspeed protection. Engine brake activation. parameter AF in VECU MID 144

46 2. Engine

EPG

Activated:

engine speed > 900 rpm

vehicle speed > 5 km/h (3 mph)

Deactivated:

engine speed < 800 rpm

vehicle speed < 5 km/h (3 mph)

VCB

Activated:

engine speed1 > 1100 rpm

vehicle speed > 5 km/h (3 mph)

engine oil temperature > 55 C (131 F)2

engine oil temperature > 60 C (140 F)3

charge air pressure < 50 kPa (7 psi)

Deactivated:

engine speed1 < 1000 rpm

vehicle speed < 5 km/h (3 mph)

engine oil temperature < 55 C (131 F)

charge air pressure > 70 kPa (10 psi)1 The value is increased to 1400 rpm for the first five activations. Applies at engine oil temperatures 55 -

82 �C (131 - 180�F).2 Oil temperature sensor combined with oil pressure sensor3 Oil temperature sensor combined with oil level sensor in oil pan

2. Engine 47

Exhaust Backpressure

Standard muffler, maximum 15 kPa (2.18 psi) (4.4 in. Hg)

Tuned muffler (D12D-465), maximum1 20 kPa (2.9 psi) (6 in. Hg)1 Oct. 02 - Jan. 04

Cooling SystemFor cooling system volumes and coolant requirements,refer to Service Information, group 18: “CoolantRequirements, Volvo Engines.”

General

Pressure valve opens at 75 kPa (10.9 psi)

FanViscous Fan (Air Sensing Fan)

Speed, engaged (engine speed @ 1800 rpm)

Fan pulley diameter 167 mm (6.57 in.) 2400 rpm



Speed, not engaged 500 - 1000 rpm

Engagement temperature 75 C (167 F) in front of fan

48 2. Engine

Electronically Controlled Viscous Fan

Activated system Condition Fan RPM Requested

Coolant temperature Start temperature 90C(194 F)

600 rpm

Coolant temperature > 93 C (199F) Variable fan speed activation

Engine ECU temperature Activation ECU temperature> 100 C (212 F),deactivates < 95 C (203

F)

1200 rpm

AC system Refrigerant pressure > 20 bar(300 psi)

Full engagement (120%of engine speed) exampleengine speed 1500 rpm x120% = 1800 approx. fanspeed

Engine speed > 1500 rpm,ambient temp > 40 C(104F), vehicle speed <45km/h (28 mph)

1200 rpm

Engine speed > 1200 rpm,ambient temp > 30 C (86F),vehicle speed < 45km/h (28mph)

1000 rpm

Ambient temp > 35 C(95F), vehicle speed <10km/h (6 mph)

1200 rpm

AC system (a/c compressormagnetic clutch activated)

Ambient temp > 20 C(68F), vehicle speed <20km/h (12 mph)

600 rpm

2. Engine 49

On-off Fan

Activation temperature 91 C (196 F)

Deactivation temperature 87 C (189 F)

Activated System Condition

Coolant temperature Activation > 91 C (196 F), deactivation 87 C (189F)

Engine ECU temperature ECU temperature > 100C (212 F), deactivates < 95C (203 F)

Intake manifold air temperature(VHD 465 hp only)

> 80 C(176 F) for more than 2.5s, deactivates below70 C(158 F) for more than 5s

AC system Refrigerant pressure > 20 bar (300 psi)

Thermostat

Quantity 1

Opening temperature 82 C (179 F)

50 2. Engine

Engine Control SystemEngine ECU

Note: The EECU may not be replaced withoutprior authorization from Volvo; refer to ServiceInformation, Engine ECU, Fault tracing, IMPACT orID DVD: Info type “Diagnostics” group 2841.

Number ofpins 2 x 62

Sensors

Charge air sensor

Check value 1.05 — 1.30 V (normal atmospheric pressure)

Intake air temperature sensor

T2019008

2. Engine 51

Coolant temperature sensor

T2019009

52 2. Engine

Intake temperature sensor

T2019010

2. Engine 53

Engine oil temperature sensor

T2019011

Camshaft sensor

Distance tocamshaft

0.3 - 1.0 mm (0.012 -0.039 in.)

Resistancemeasurement 775 - 945

Flywheel sensor

Distance toflywheel

0.7 - 2.1 mm (0.028 -0.083 in.)

Resistancemeasurement 775 - 945

54 2. Engine

Crankcase Pressure Sensor

Sensor alarm limit > 8 kPa (1.2 psi)

Crankcasepressure: normalvalue (VEB notactive) regardlessof engine speed,maximum

1.0 kPa (0.13 psi)‘

2. Engine 55

Tightening Torques and Patterns

Group 20Tightening

M6 standard screw 8.810 ± 1.5 7.4 ± 1 Nm (89 ± 13inch-lb)

M8 standard screw 8.8 24 ± 4 Nm (18 ± 3 ft-lb)





Only torque-tightened screws may be reinstalled.

Torque and angle tightened / yield point screws:

8.8 must not be reinstalled

10.9 may be reinstalled

12.9 may be reinstalled

Note: Check the screw that is being reinstalled. A damaged screw (e.g. with tear damageunder the head) must be replaced.

56 2. Engine

Group 21Tightening: Torque Angle

Front engine mounting, cylinder block 175 ± 20 Nm (129 ± 15ft-lb

Front engine mounting, crossmember 85 ± 15 Nm (63 ± 11ft-lb)

Rear engine mounting, flywheel casing 245 ± 35 Nm (181 ± 27ft-lb)

Rear engine mounting, rubber cushion

step 1 175 ± 5 Nm (129 ± 4ft-lb)

step 2 255 ± 38 Nm (188 ± 28ft-lb)

Main bearing cap

step 1 150 ± 20 Nm (110 ± 15ft-lb)

step 2 120 ± 5

Connecting rod cap

step 1 275 ± 15 Nm (204 ± 11ft-lb)

2. Engine 57

T2014149

Stiffening frame, tightening sequence

Tightening: Torque Angle

Stiffening frame

step 1: tighten screws 1-6 in sequence 48 ± 8 Nm (36 ± 6 ft-lb)

step 2: tighten screws 7-26 in sequence 15 Nm (11 ft-lb) 90 ± 5

Piston cooling valve, screw1 24 ± 4 Nm (18 ± 3 ft-lb)1 screws may not be reused.

58 2. Engine

T2006973

Flywheel, tightening sequence (ensure that flange is dry and clean).


Flywheel (tighten screws in numerical order as illustrated):

step 1 60 ± 5 Nm (44 ± 4 ft-lb)

step 2 60 ± 5

2. Engine 59

T2019062

Flywheel housing, tightening sequence.


Flywheel housing

Note: Apply a string of silicone as illustrated,thickness 2 mm (0.08 in.), max. 20 minutesbefore assembly.

140 ± 14 Nm (105 ± 10ft-lb)

60 2. Engine

T2014027

Vibration damper, VN —tightening sequence.

W2004219

Vibration damper, VHD —tightening sequence.


Vibration damper

step 11 ....................................................... 20 ± 5 Nm (15 ± 4 ft-lb)

step 2 .........................................................................................................90 ± 5

Note: Screws may NOT be reused if they have been tightened with torque and angle.1 Following the numerical order, tighten screws according to step 1 before tightening according to step 2.

2. Engine 61

T2012845

Valve cover, tightening sequence

Note: If the valve cover is replaced, a new EngineCertification Label must be printed and affixed to the newvalve cover. A new label can be printed from VCADSPro “Engine Label Print” group 2.

Tightening: Torque

Valve cover (tighten screws in order as illustrated) 20 ± 2 Nm (15 ± 1.5 ft-lb)

Stud, valve cover 40 ± 3 Nm (29 ± 2 ft-lb)

62 2. Engine

T2007004

Cylinder head, tightening sequence


Cylinder head (tighten screws in order as illustrated):

step 1 60 ± 10 Nm (44 ± 7 ft-lb)

step 2 (check tightening) 60 ± 10 Nm (44 ± 7 ft-lb)

step 3 90 ± 5

step 4 (turn additional) 90 ± 5

Cleaning plug, cylinder head 60 ± 10 Nm (44 ± 7 ft-lb)

Lock nut, valve adjustment screw:

Option 1 38 ± 4 Nm (28 ± 3 ft-lb)

Option 260 ± 5after contact

Lock nut, valve yoke (EPG)60 ± 5after contact

Lock nut, valve yoke (VEB)60 +10/-0after contact

2. Engine 63

T2012850

Bearing cap, camshaft/rocker arm shaft, tightening sequence


Bearing cap, camshaft/rocker arm shaft

step 1 15 ± 5 Nm (11 ± 4 ft-lb) 90 ± 5

step 21 60 ± 5 Nm (44 ± 4 ft-lb)

step 3 15 ± 5 Nm (11 ± 4 ft-lb) 120 ± 5

step 4 (loosen the screws)

step 5 15 ± 5 Nm (11 ± 4 ft-lb) 120 ± 51 Screws must be tightened in stages to ensure that the rocker arm shaft comes down without bending.

64 2. Engine

T2019046

Timing gear cover, lower

Tightening: Torque

Timing gear cover, lower:

Step 1: Apply a thin bead1 of silicone as illustrated, including around the marked holeno more than 20 minutes before assembly.

Step 2: Working from center outward, tighten to 34 ± 4 Nm (24 ± 3 ft-lb)1 Solid line = 2 mm bead; dashed line (area A) = 1 mm bead.

2. Engine 65

T2019925

Timing gear cover, upper

Note: When the upper timing gear cover is installed, the top section mustbe flush with the cylinder head.

Tightening: Torque

Timing gear cover, upper:

Step 1: Apply a thin bead of silicone1 as illustrated, including around the marked holes,no more than 20 minutes before assembly.

Step 2: Tighten screws in order as illustrated:

M8 24 ± 4 Nm (18 ± 3 ft-lb)

M10 48 ± 8 Nm (36 ± 6 ft-lb)1 Thickness 2 mm.

66 2. Engine

W2004477

Gear train

Timing gears: use the following torques(and angles, when indicated) for the

corresponding gear; follow the tighteningsequence for each gear as illustrated.


A. Camshaft gear 35 ± 3 Nm (26 ± 2 ft-lb) 90 ± 5

B. Adjustable idler (intermediate) gear 15 ± 3 Nm (11 ± 2 ft-lb) 120 ± 5

C. Intermediate gear 15 ± 3 Nm (11 ± 2 ft-lb) 120 ± 5

D. Idler/intermediate gear 24 ± 4 Nm (18 ± 3 ft-lb)

E. Crankshaft gear (polygon hub) 645 ± 25 Nm (476 ± 18ft-lb)

F. Idler gear 15 ± 3 Nm (11 ± 2 ft-lb) 120 ± 5

2. Engine 67

Group 22

T2017885

Oil pan, tightening sequence

Tightening: Torque

Oil pan (tighten bolts in order as illustrated) 24 ± 3 Nm (18 ± 2 ft-lb)

Drain plug, oil pan 60 ± 10 Nm (44 ± 7 ft-lb)

Bracket, oil pump/main bearing cap 24 ± 3 Nm (18 ± 2 ft-lb)

Oil strainer, mounting screws in pump 27 ± 3 Nm (20 ± 2 ft-lb)

Oil cooler, mounting screws 27 ± 3 Nm (20 ± 2 ft-lb)

68 2. Engine

T2006701

Delivery pipe

T2006825

Delivery Pipe Torque Angle

Step 1:

Tighten fitting in cylinder block until itbottoms; approximately

10 Nm (88 in-lb)

Step 2:

New pipe 180

Pipe being reinstalled 60

2. Engine 69

T2014088

Oil cooler, cover; always use guide pins when installing the cover on theengine.

Tightening: Torque

Oil cooler, cover

Mount screws A and B 24 ± 4 Nm (18 ± 3 ft-lb)

Tighten C and D 24 ± 4 Nm (18 ± 3 ft-lb)

Tighten cover screws in numerical order from themiddle outwards (1–4); see illustration

24 ± 4 Nm (18 ± 3 ft-lb)

Check tighten screws A and D 24 ± 4 Nm (18 ± 3 ft-lb)

70 2. Engine

Group 23Tightening: Torque Angle

Retainer, unit injector(new copper sleeve)

First tightening

step 1 20 ± 5 Nm (15 ± 4 ft-lb)

step 2 180 ± 5

Loosen the retainer screw before the second tightening.

Second tightening

step 1 20 ± 5 Nm (15 ± 4 ft-lb)

step 2 60 ± 5

Retainer, unit injector (reused copper sleeve)

step 1 20 ± 5 Nm (15 ± 4 ft-lb)

step 2 60 ± 5

Lock nut for adjustment screw, unit injector:

Option 1 52 ± 4 Nm (38 ± 3 ft-lb)

Option 2 45 ± 5

Banjo screw, 10 mm 12 ± 2 Nm (108 ± 22inch-lb)

Banjo screw, 14 mm 35 ± 4 Nm (26 ± 3 Ft-lb)

Banjo screw, 16 mm 40 ± 5 Nm (30 ± 4 ft-lb)

2. Engine 71

Group 25

W2004483

Exhaust manifold

Exhaust manifold (refer to illustration for tighteningsequence): Torque

1. Tighten bolts 1 to maximum 10 Nm (88 inch-lb)

2. Tighten bolts 2 to maximum 10 Nm (88 inch-lb)

3. Tighten bolts 3 to 52 ± 4 Nm (38 ± 3 ft-lb)




Tightening Torque

Clamp, exhaust manifold (“A” in illustration) 10 ± 1 Nm (71 ± 8 inch-lb)

Exhaust pressure governor (EPG) turbine housing 24 ± 2 Nm (18 ± 1.5 ft-lb)

Control valve (VEB) 20 ± 3 Nm (15 ± 2 ft-lb)

Nut electrical connector, VEB-valve 1.5 ± 0.5 Nm (13 ± 4 inch-lb)

V-clamp, turbocharger housing 8.5 Nm (75 inch-lb)

72 2. Engine

EGR System

W2004292

Tightening Torque

EGR Pipes:

V-clamp 10 ± 2 Nm (88 ± 17 inch-lb)

Hose clamp, mixing chamber 5 ± 1 Nm (35 ± 9 inch-lb)

Vibration Damper Assembly:

Bracket 15 ± 3 Nm (133 ± 3 inch-lb)

Vibration Damper 24 ± 4 Nm (18 ± 3 ft-lb)

2. Engine 73

W2004261

Tightening sequence for EGR cooler mounting brackets

Note: Older version shown. Newer engineversion “number 1” in the image has been

removed. Front and rear bracket are the sameon newer engines.

Tightening Sequence Torque

EGR cooler mounting bracket, rear tensioning band:

1. Screw (against washer) 24 ± 4 Nm (18 ± 3 ft-lb)

2. Screw/lock nut 12 ± 2 Nm (106 ± 17 inch-lb)

EGR cooler mounting bracket, front tensioning band:

3. Screw/lock nut 12 ± 2 Nm (106 ± 17 inch-lb)

Group 26Thermostat, mounting bolts Torque

Bolt grade 8.8 24 ± 4 Nm (18 ± 3 ft-lb)

Bolt grade 10.9 30 ± 4 Nm (22 ± 3 ft-lb)

74 3. Electrical System and Instruments

SpecificationsFuse and Relay LocationsThe vehicle’s instrumentation, gauges andother electrically controlled parts are wiredthrough the Truck Electrical Center (TEC).The TEC is located in the center of the dash,just above the engine cover.

The vehicle has two electrical centers, onelocated in the middle of the dash under thetop cover, and the other under the frontcover. The electrical center underneath thefront cover is the power module and it feedsthe relays to the electrical center under thetop cover.

Located just below the fuse/relay panelare the following modules: VehicleECU/Bodybuilder module, Light ControlModule, Steering Wheel Module and CentralLocking Module/relay.

Refer to the decal inside the TEC cover forvehicle’s exact fuse locations and ratings.(Note that all fuses and relays may not beused in every vehicle.)

The TEC panel includes all maxi-fuses,mini-fuses, relays and micro-relays.Maxi-fuses are designed for larger amountsof current than regular fuses. The micro ISOrelays are smaller in size than conventionalrelays, and the pin arrangement is different.Mini-fuses are also smaller in size, but thecurrent rating is the same as ATO-size fuses.

W3005285

TEC in Center Dash

3. Electrical System and Instruments 75

Tightening Torques

Delco 42MT Melco Gear Reduction Delco 39 MT HD

1 Solenoid2 Shift Lever

Housing3 Nose Housing4 Pinion5 Overcrank

Protection InputConnector

1 Solenoid2 Heavy-duty Relay3 Pinion

Startersolenoidstud nut

30.5 ± 3.5 Nm(22 ± 2.6 ft-lb)

25 ± 5 Nm(18 ± 3.7 ft-lb)

26 ± 1.5 Nm(19 ± 1.1 ft-lb)

Startergroundstud

30.5 ± 3.5 Nm(22 ± 2.6 ft-lb)

25 ± 5 Nm(18 ± 3.7 ft-lb)

26 ± 1.5 Nm(19 ± 1.1 ft-lb)

Batterycables (+and -)

19 ± 1Nm(14 ± 1 ft-lb)

Mainpowerstuds (atcab pass-through)

10 ± 2 Nm(88 ± 17 in-lb)

Maingroundstuds (atcab pass-through)

10 ± 2 Nm(88 ± 17 in-lb)


Torque Specifications for Ring Terminals

Cab 12V Power Connections Torque Specification

Pass-through power stud 10 ± 2 Nm (89 ± 18 in-lb)

Engine Block

Engine block ground 19 ± 1 Nm (14 ± 0.7 ft-lb)

Starter Motor

Main power and ground 30.5 ± 3.5 Nm (22.5 ± 2.6 ft-lb)

Solenoid stud (Delco 42MT, Melco) 2.8 ± 0.8 Nm (24 ± 7 in-lb)

Starter—mounted relay (Delco 39 MT HD) 2.25 ± 0.25 Nm (20 ± 2 in-lb)

Alternator (33SI/34SI)

Battery terminal — circuit 8 6.9 ± 0.5 Nm (61 ± 5 in-lb)

Ground terminal — circuit 0A 6.1 ± 0.5 Nm (54 ± 5 in-lb)

“I” terminal — circuit 14 2.4 ± 0.5 Nm (22 ± 5 in-lb)

“R” terminal — circuit 16 2.4 ± 0.5 Nm (22 ± 5 in-lb)

Alternator (22SI)

Battery terminal — circuit 8 6.5 ± 0.5 Nm (58 ± 5 in-lb)

Ground terminal — circuit 0A 6.1 ± 0.5 Nm (54 ± 5 in-lb)

“I” terminal — circuit 14 2.4 ± 0.5 Nm (22 ± 5 in-lb)

“R” terminal — circuit 16 2.4 ± 0.5 Nm (22 ± 5 in-lb)

Preheater Relay)

Power stud 5.7 ± 0.6 Nm (50 ± 5 in-lb)

Coil stud 1.7 ± 0.3 Nm (16 ± 2 in-lb)

Preheater Assembly

Brass Nut 12.5 ± 1.5 Nm (110 ± 13 in-lb)

Flange screw 14.5 ± 1.5 Nm (128 ± 13 in-lb)

Bulkhead

Engine-side ground studs 6 ± 1 Nm (53 ± 8 in-lb)

Starter relay

Power stud 5.7 ± 0.6 Nm (50 ± 5 in-lb)


Group 35 — Light Control Module

W3005269

T3014623

The Light Control Module (LCM) controls allexterior lighting functions. Interior lightingin the cab and optional “extras” installedon the vehicle are not part of this system.In addition, it controls the intermittentwindshield wiper function and the wiper

function when the windshield washer isused. The control unit communicates via theJ1587/1708 information link and the J1939control data link as MID 216. See “MID216” page 10


Light Switch

W3005328

1. Light Switch2. Hazard Warning lightsswitch/Hazard warning lightsindicator light3. Rheostat for instrument lightingA. “Off”B. ParkC. DriveD. Drive+

Note: Only premium version havethe “Drive+” position.


W3005328

Light Switch Troubleshooting

The LCM operates by interpreting a combination of ground and open signals from terminals1 & 2 on the back of the Light Switch.

To test switch functions• Set multimeter to Ohms (resistance)• Connect black lead of multimeter to terminal 16 (ground).• Probe terminals 1 or 2 with the red lead.The chart below demonstrates the expected meter readings by switch position and terminal.

TerminalPosition

1 2

Function

0ff (A) Open ≈ 0 Daytime running lights

Parking lights(B)

≈ 0 ≈ 0 Daytime running lights, Tail lights, Parkinglights, Side marker lights

Headlights (C) Open Open High beam / low beam, Tail lights, Parkinglights, Side marker lights

Headlights withauxillary lights

(D)

≈ 0 Open High beam / low beam, Auxiliary lights(driving/fog), Tail lights, Parking lights, Sidemarker lights

80 5. Brakes

SpecificationsDrum Brake

Brake Slack Adjusters and Cam

W5001492

DANGER

Before checking the slack adjusters, setthe parking brakes, place the transmissionin neutral, and block the wheels. Failureto do so can result in unexpected vehiclemovement and can cause serious personalinjury of death.

To check the slack adjusters for proper throw,use a breaker bar to lever the slack adjusterout. Measure the distance of the travel. Itshould not exceed 25 – 30 mm (1 – 1.25 in)for a 6 inch slack adjuster and should notexceed 20 — 25 mm (.75 — 1 in) for a 5.5inch slack adjuster. Also make sure that thelength of the slack adjuster is the same onan axle.

Note: Travel is measured from the chamberface as shown in the illustration.

5. Brakes 81

Brake Linings

W7001278

DANGER

Before measuring linings, set the parkingbrakes, place the transmission in neutral,and block the wheels. Failure to do so canresult in unexpected vehicle movementand can cause serious personal injury ofdeath.

Measure the brake lining thickness, If thebrakes are equipped with backing plates,measure through the inspection holes in theplate. Reline the brake shoes if the liningthickness is 6 mm (.25 in) or less at themiddle of the shoe.

Note: Check the brake drums for and visiblecracks or signs of oil or grease.

82 5. Brakes

Compressor

1COMP530

T5012037

Model ........................................................................WABCO 352

Volvo part no. D12 engine .......................................20382348

Type ..........................................................................Piston compressor

Number of cylinders .................................................1

Cooling, cylinder head ..............................................Fluid

Cooling, cylinder ......................................................Air

Air capacity at back pressure of 800 kPa (8 bar) andcompressor speed of 2000 rpm .................................440 dm³/min

Max operating pressure .............................................1300 kPa (13 bar)

Max operating speed .................................................3000 rpm

Cylinder bore ............................................................85 mm (3.34 in.)

Stroke ........................................................................62 mm (2.44 in.)

Swept volume ...........................................................352 cm³ (21 in³)

PR function:

Cylinder stroke PR-piston reed valve .......................10-15 mm (.39-.59 in.)

5. Brakes 83

Tightening Torques

Tightening: Torque - Nm (ft-lb) Angle

Drive gear wheel ....................................... 200 - 250 (147 - 184)

Union, outlet pipe ..................................... 130 ± 20 (95 ± 14)

Unions for oil hoses, compressor and engineblock ..........................................................

25 ± 4 (18 ± 2.9)

Cylinder head bolts, 4pcs (1-4). Refer toillustration below for correct tighteningsequence ....................................................

25 ± 2 (18 ± 1.4) 90

Bolted joints, valve plate 4pcs (5-8). Referto illustration below for correct tighteningsequence ....................................................

10 ± 1 (7.3 ± .7) 90

Union, PR connection to compressor ....... 25 ± 4 (18 ± 2.9)

Bolted joint, compressor mounting ........... 85±15 (62 ± 11)

T5012871

84 5. Brakes

2COM1080 VERSION2

T5012038

Make .........................................................................WABCO 704

Volvo part no. D12 engine .......................................20382347

Type ..........................................................................Piston compressor

Number of cylinders .................................................2

Cooling, cylinder head ..............................................Fluid

Cooling, cylinder ......................................................Air

Air capacity at back pressure of 800 kPa (8 bar) andcompressor speed of 2000 rpm .................................800 dm³/min

Max operating pressure .............................................1300 kPa (13 bar)

Max operating speed .................................................3000 rpm

Cylinder bore ............................................................85 mm (3.34 in)

Stroke ........................................................................62 mm (2.44 in)

Swept volume ...........................................................704 cm³ (43 in³)

PR function:

Cylinder stroke PR-piston reed valve .......................10-15 mm (.39 - .59 in)

5. Brakes 85

Tightening Torques

Tightening: Torque - Nm (ft-lb) Angle

Drive gear wheel ....................................... 200 - 250 (147 - 184)

Union, outlet pipe ..................................... 130 ± 20 (95 ± 14)

Unions for oil hoses, compressor and engineblock ..........................................................

25 ± 4 (18 ± 2.95)

Cylinder head bolts 6pcs (1-6).

Note: After the screws (1-6) are torquedtight, check by turning screw (1) once again.

Refer to illustration below for correcttightening sequence ...................................

25 ± 2 (18 ± 1.47) 90

Valve plate bolts 4pcs (7-8). Refer toillustration below for correct tighteningsequence ....................................................

7 ± 2 (5 ± 1.47) 90

Nipple, PR connection to compressor ....... 25 ± 4 (18 ± 2.95)

Bolted joint, compressor mounting ........... 85 ± 15 (62 ± 11)

T5012835

86 5. Brakes

Air Drier

Wabco SS1200PHeight 284 mm (11.2 in.)

Voltage ..................... 12 V

Working Pressure ..... 10.3 bar (150 psi)

Maximum flowcapacity ...................

1416 L/min (50 cfm)

Heater power ............ 100 W

Wabco System Saver TwinHeight ....................... 322 mm (12.6 in.)

Maximum width ....... 320 mm (12.6 in.)

Voltage ..................... 12 V

Working Pressure ..... 10.3 bar (150 psi)

Maximum flowcapacity ...................

1416 L/min (50 cfm)

Heater power ............ 100 W

Bendix ADIPHeight ....................... 360 mm (14.18 in.)


Weight ...................... 13 kg (28 lb)

Voltage ..................... 12 V

Maximum flowcapacity ....................

850 L/min (30 cfm)

Heater power ............ 90 W

5. Brakes 87

Bendix AD-9Height ....................... 360 mm (14.25 in.)


Weight ...................... 13 kg (28 lb)

Voltage ..................... 12 V or 24 V


481 L/min (17 cfm)


Midland Pure Air PlusHeight ....................... 384 mm (15.1 in.)


Weight ...................... 8 kg (18 lb)

Voltage ..................... 12 V


710 L/min (25 cfm)


88 5. Brakes

CR Turbo 2000Height ....................... 413 mm (16.25 in.)


Weight ...................... 7.5 kg (16.5 lb)

Voltage ..................... 12 V


850 L/min (30 cfm)


5. Brakes 89

Brake Valves

Treadle ValveMain brake actuation valve, foot operated.

Make, Model Bendix, E–6

Max operating pressure 150 PSI (10.3 bar)

Connections, all 3/8” NPTF• Rear brake supply 11, 2 ports• Rear brake delivery 21, 2 ports• Front brake supply 12, 2 ports• Front brake delivery 22, 2 ports

Park Brake Control ValveDash mounted valve for application andrelease of park brake system.Single button valve

Make Meritor Wabco


Control of park brakes for vehicles notintended to pull trailer.

Connections, all Push-To-Connect (PTC)built-in cartridges• Rear circuit air reservoir• Front circuit air reservoir• Exhaust• Air delivery to park brakes

90 5. Brakes

(Park Brake Control Valve continued)Dual button valve

Make Meritor Wabco


Control of park brakes for vehicles intendedto pull trailer.

Connections, all Push-To-Connect (PTC)built-in cartridges• Rear circuit air reservoir• Front circuit air reservoir• Exhaust• Air delivery to truck park brakes• Air delivery to trailer• Auxiliary port (supplies blended air for

aux. brake control valves

Hand Control ValveDash mounted brake application valvegenerally used to apply trailer brakes

Make Meritor Wabco


Pressure delivery Modulated pressure from 0 to systempressure depending on handle position.

Connections, all Push-to-Connect (PTC)built-in cartridges.• Supply port• Delivery port• Exhaust port

5. Brakes 91

Quick Release ValveFor rapid release of brake application air onthe front wheels.

Make Meritor Wabco


Crack pressure 3 PSI (0.2 bar)

Connections

Supply port 1/2” NPTF

Delivery port 3/8” NPTF

Quick Release Valve with Double CheckFor rapid release of park brake air on the rearwheels. Use for tractors.

Make Meritor Wabco


Connections


Anti-compounding port 1/4” NPTF

Delivery port 3/8” NPTF

92 5. Brakes

Inversion Relay ValveFor application and release of parking brake.In the event of an emergency due to airpressure loss in the primary air reservoir(rear air brake circuit), this valve allowsmodulated control of the rear brakes throughthe spring brake chambers by use of thesecondary air control (front brake circuit).

Make Meritor Wabco


Max spring break hold off pressure 105 PSI (7.2 bar)

Port Connection

Supply port, primary air 1/2” Push-to-Connect (PTC)

Supply port, secondary air 1/2” PTC

Delivery ports, 4 ports 3/8” NPTF

Primary brake control 1/2” PTC

Secondary brake control 3/8” PTC

Park brake control 3/8” PTC

5. Brakes 93

Tractor Protection ValveUsed on trucks intended to pull a trailer.Protects system air pressure on the towingvehicle in the event of a trailer breakaway.

Make Meritor Wabco


Port Connection

Supply port, from hand control valve 3/8” Push-to-Connect (PTC)

Supply port, for primary brake control 1/2” PTC

Supply port, from secondary brake control 3/8” PTC

Supply port, trailer emergency air 3/8” PTC

Stop light switch signal 1/4” PTC

Delivery port, trailer service brakes 1/2” NPTF

Delivery port, trailer emergency air 1/2” NPTF

Air GovernorMake Meritor Wabco

Max. operatingpressure

150 psi

Cut-in pressure 110 psi

Cut-out pressure 130 psi

All ports 1/8” NPTF

94 5. Brakes

Relay Valve and ABS Modulator Valves AssemblyRear brake control valving, can also includean additional solenoid valve in the assemblyfor traction Control function.

Make Meritor Wabco


Crack pressure 5.5 PSI (0.4 bar)

Port Connection

Control port 1/4” NPTF


Delivery ports, 4 ports 1/2” NPTF

Safety ValveOver pressurization protection mounted inthe wet tank.

Make Meritor Wabco

Max operating pressure 150 PSI (10.3 ± 0.7 bar)

One Way Check ValvesLocated in the primary and secondary airreservoirs to protect against air loss, one ineach air tank.

Make Norgren or Bendix depending on the air tankinstalled.

5. Brakes 95

Pressure Protection Valve ManifoldFrame mounted valve with multiple deliveryports. Purpose is to supply air to allnon-brake related systems. Protects the mainbrake air by disallowing pressure loss in themain air system lower than 70 psi in the eventof a non brake related system failure/leak.

Port Connection

Control port Meritor Wabco

Supply port 150 psi (10.3 bar)

Opening pressure 85±10 psi (5.9±0.7 bar)

Closing pressure 67±7 psi (4.6±0.5 bar)

Port Connection

Supply port 1/2” PTC

Delivery ports, 3 ports 1/4” PTC

Delivery ports, 4 ports 3/8” PTC

96 5. Brakes

Pneumatic Electric Interface Panel

W5001392

1 AP-TD Application air pressure, transducer

2 REAR SUP Rear air suspension, transducer

3 SLS Stop light switch

4 FRT SUP Front air suspension, transducer

5 PBS Parking brake, switch

6 B-TD “B” tank, transducer

7 PARK Pneumatic connection/air line connection

8 A-TD “A” tank transducer

9 B-Tank Pneumatic connection/air line connection

10 A-Tank Pneumatic connection/air line connection

11 Cab power supply (+ —)

6. Suspension and Steering 97

SpecificationsWheel Alignment

The following alignment specifications represent theindustry standard established for a mid point target valueon wheel alignment. Setting alignment for the target valueminimizes inherent variations in measurement systemsand provides optimum tire life. All values given in thetable are for unladen vehicles with no trailer connected.

Note: Actual measurement can vary and still meetfactory specifications. Contact the original equipmentmanufacturer for specification questions.

Steer Axle:

Toe-In ........................................................................1.5 mm (1/16 in.) 0.08

Camber ......................................................................Less than 1/4 (2)

Caster ........................................................................+2.5 ± 1.0

Drive Axle:

Thrust angle (Square) ................................................0.0 or 0 in.

Scrub (Parallelism) 0.0 or 0 in.

Lateral Offset 0 in.

Trailer Axles & Dollies:

Thrust angle (Square) ................................................0.0 or 0 in.

Scrub (Parallelism) 0.0 or 0 in.

Lateral Offset 0 in.

NOTES:

1. All specifications are measured with vehicle in static, unladen condition.

2. Camber angle changes normally involve bending the axle beam, which may void the axlemanufacturer’s warranty. If the measurement exceeds this value consult the vehicle, axle,and/or alignment equipment manufacturer.

98 6. Suspension and Steering

Steering

Steering Wheel/Adjustment, Steering ColumnClearance in steering wheel universal joints, lowersteering column1 ........................................................

Zero slack

Elasticity/slack in lower steering column, steering columnin working position and turned with ± 10 Nm..............

1.2�

Elasticity/slack in lower steering column, steering columnin working position and turned with ± 20 Nm..............

1�

Distance between locking device forks........................ 59 ± 1 mm (2.3 ± 0.03 in.)

Maximum distance between pedal upper bend - notch inpedal anchorage..........................................................

5 mm (0.19 in.)

1 When the steering column is pulled out, outside the ordinary driving position, slack is permissible

Power Steering GearModel TRW TAS-65 Sheppard

M100TRW THP60 TRW TAS 85

Type Ball nut Ball nut Ball nut Ball nut

Ratio 18.4:1 18.9:1 18.2: 1 21.0:1

Steering wheeltravel

4.5 turns 4.75 turns 4.75 turns 4.75 turns

Max. outputtorque

43,050 in-lb (@2175 psi)

43,050 in-lb (@2175 psi)

43,6000 in-lb(@2682 psi)

58,850 in-lb (@2175 psi)

6. Suspension and Steering 99

Power Steering PumpEngine VOLVO D12 Cummins CU15 (ISX)

Rotation cw cw

Drive type gear splineDisplacement /rev (cm3) 18 (VN)

18-25 (VHD)22-25 (VN)22-36 (VHD)

Oil type Dexron II or Dexron III

Pressure output (max) 18.5 MPa (2683 psi)

Pressure output (min) 12.5 MPa (1800 psi)

Regulated Flow 16 liters/min (4.2 gpm)

System VHD VN

Oil capacity 4.7 liters (1.25 gal) 2.8 liters (0.74 gal)

100 6. Suspension and Steering

Tightening TorquesSteering Wheel

Steering wheel center bolt 85 ± 15 Nm (63 ± 11 ft-lb)

Note: Steering wheel center bolt is not tobe reused

Steering Column

Upper steering column attachmentbolts

15 ± 3.5 Nm (135 ± 30 in-lb)

Gas spring bolts 17 ± 3 Nm (150 ± 25 in-lb)

Steering Shaft

Steering shaft U-joint pinch bolts 60 ± 10 Nm (45 ± 7 ft-lb)

Steering Gear

Pitman arm retainer (Sheppard) as marked on retainer

Pitman arm pinch bolt (TAS) 400 ± 60 Nm (295 ± 45 ft-lb)

Pitman arm jam nut (ZF) 600 ± 50 Nm (445 ± 37 ft-lb)

Mounting bolts, steering gear 540 ± 90 Nm (400 ± 67 ft-lb)

Pitman arm/drag link 200 ± 30 Nm (148 ± 22 ft-lb)

Power Steering Pump

Housing bolts 45 ± 5 Nm (33 ± 4 ft-lb)

Mounting bolts 46 ± 1 Nm (34 ± 1 ft-lb)

7. Chassis, Springs, Damping, and Wheels 101

SpecificationsSuspension

Location Diameter Grade Torque

U-Bolts for Suspension

VN Front MechanicalSuspension

M20550 Nm (405 ft-lb)

VN Front Air Suspension M20 420 Nm (310 ft-lb)

VHD Front Suspension M20 550 Nm (405 ft-lb)

M16 200 Nm (150 ft-lb)VN, VHD Volvo T-RideRear Suspension(38,000 —46,000 lbs.)

M20 500 Nm (370 ft-lb)

M20 350 Nm (260 ft-lb)VN, VHD Volvo T-RideRear Suspension(48,000 —70,000 lbs.)

M24 600 Nm (445 ft-lb)

VN, VHD Volvo Multi-leafRear Suspension (4x2)

M22 500 Nm (370 ft-lb)

M20 500 Nm (370 ft-lb)VN Volvo Rear Suspension(VOAS)

M24 575 Nm (425 ft-lb)

Radius Spring to Spring HangerBracket

M16 8.8 275 ± 45 NM (203 ± 33 ft-lb)

Air Spring Crossbeam(Pedestal) to Leaf

M12 10.9 105 ± 20 Nm (77 ± 15 ft-lb)

Air Spring to Crossbeam(Pedestal)

M12 8.8 50 ± 10 Nm (37 ± 7.5 ft-lb)

Torque Rod to Frame-MountedBracket

M16 10.9 320 ± 50 Nm (236 ± 37 ft-lb)

Torque Rod to Axle Housing M16 10.9 320 ± 50 Nm (236 ± 37 ft-lb)

Shock Absorber Bracket toFrame

M14 10.9 200 ± 45 Nm (148 ± 33 ft-lb)

Shock Absorber to Bracket(Upper and Lower)

M16 8.8 275 ± 45 Nm (203 ± 33 ft-lb)

Bracket for Load LevelingValve to Frame

M14 10.9 200 ± 45 Nm (148 ± 33 ft-lb)

102 7. Chassis, Springs, Damping, and Wheels

Location Diameter Grade Torque

Load Leveling Valve ControlArm to Lever on Valve and AirBag Pedestal

M6 8.8 10 ± 1.5 Nm (7 ± 1 ft-lb)

Spring Hanger Bracket toFrame

M14 10.9 200 ± 45 Nm (148 ± 33 ft-lb)


Ride Height and Pinion Angle SpecificationsFrame Height, mm (in.) Ride Height mm (in.) Pinion Angle

(Drive axle 1)Pinion Angle(Drive axle 2)

Meritor RT40-145

266 (10.47) axle space 1320 220 ± 5 (8.7 ± 0.2) 2.5 ± 1 13.0 ± 1

RRH 200 axle space 1520 220 ± 5 (8.7 ± 0.2) 2.5 ± 1 11.5 ± 1

300 (11.81) axle space 1320 203 ± 5 (8 ± 0.2) 2.5 ± 1 13.0 ± 1

RRH 180 axle space 1520 203 ± 5 (8 ± 0.2) 2.5 ± 1 11.5 ± 1

266 (10.47) axle space 1320 180 ± 5 (7.1 ± 0.2) 2.5 ± 1 13.0 ± 1

RRH 160 axle space 1520 173 ± 5 (6.8 ± 0.2) 1.8 ± 1 12.2 ± 1

Dana 404

266 (10.47) axle space 1320 220 ± 5 (8.7 ± 0.2) 2.5 ± 1 12.0 ± 1

RRH 200 axle space 1520 220 ± 5 (8.7 ± 0.2) 2.5 ± 1 10.5 ± 1

300 (11.81) axle space 1320 203 ± 5 (8 ± 0.2) 2.5 ± 1 12.0 ± 1

RRH 180 axle space 1520 203 ± 5 (8 ± 0.2) 2.5 ± 1 10.5 ± 1

266 (10.47) axle space 1320 163 ± 5 (6.4 ± 0.2) 1.8 ± 1 11.3 ± 1

RRH 160 axle space 1520 161 ± 5 (6.3 ± 0.2) 1.6 ± 1 11.1 ± 1

DST 40

266 axle space 1320 220 ± 5 (8.7 ± 0.2) 2.5 ± 1 8.0 ± 1

RRH 200 axle space 1550 220 ± 5 (8.7 ± 0.2) 2.5 ± 1 2.5 ± 1

300 axle space 1320 203 ± 5 (8 ± 0.2) 2.5 ± 1 8.0 ± 1

RRH 180 axle space 1550 203 ± 5 (8 ± 0.2) 2.5 ± 1 2.5 ± 1

Meritor MT40–14M

266 axle space 1350 220 ± 5 (8.7 ± 0.2) 2.5 ± 1 2.5 ± 1

RRH 200 axle space 1550 220 ± 5 (8.7 ± 0.2) 2.5 ± 1 2.5 ± 1

300 axle space 1350 203 ± 5 (8 ± 0.2) 2.5 ± 1 2.5 ± 1

RRH 180 axle space 1550 203 ± 5 (8 ± 0.2) 2.5 ± 1 2.5 ± 1


Frame Height, mm (in.) Ride Height mm (in.) Pinion Angle(Drive axle 1)

Pinion Angle(Drive axle 2)

4X2 VOAS with any Axle

266 (10.47) 220 ± 5 (8.7 ± 0.2) 3.5 ± 1

RR H200

Table 1. Ride Height and Corresponding Pinion Angle as measured from the axle center tothe frame rail bottom (unloaded).As measured from the axle center to the frame rail bottom. *In the event that both the rideheight and pinion angles can not be adjusted at the same time for 6X4s, the ride heightshould be adjusted to the minimum cancellation error angle for the intermediate prop shaft,then lowered by 10 mm.

Note: Working angles are measured at theforward axle joint or rear axle joint.


Suspension ApplicationsNote: There are different vehicle suspension ride height(RRH) versions. RRH-180 and RRH-220 has a stampedsheet metal torque rod bracket with Meritor RT-40-145axles. All other axles have cast iron torque rod brackets.RRH-160 has always had cast iron torque rod brackets.

Available AxlesSuspen-

sion Con-figuration

MaximumGAWR

Metric Ton(lb)

MaximumGCW

Metric Ton(lb)

AxleSpacingmm (in.)

RequiredNumber of

ParkingChambers

ModelsMetric Ton

(lb)

4x2 9 (20,000) N/A TWOEaton

Meritor10

(23,000)

17(38,000)

1320 (52)TWO (1st

Axle)

18(40,000)

1320 (52) FOUR6x4

18(40,000)

50(110,000)

(1)

1524 (60) FOUR

EatonMeritor

18(40,000)

(1) GCW (Gross Combination Weight) rating can be reduced by vehicle operatingapplications, engine horsepower/torque, axle type/model, axle ratio, and/or vehicle tire size.


Wheels

Drive Axle Shaft Nuts, Tightening TorqueFastener Torque Values

ThreadSize (in.)

Lock Nut

0.75 - 16 372 ± 34 Nm(275 ± 25 ft-lb)

Fastener Torque Values

ThreadSize (in.)

Lock Nut

M14 x 2 150 ± 15 Nm(110 ± 10 ft-lb)

Fastener Torque Values

ThreadSize (in.)

Lock Nut

5/8 135 ± 20 Nm(100 ± 15 ft-lb)


Wheel Nuts, Tightening Torque

W7000774

Tightening sequence

All disc wheels for the VN and VHD-serieshave nuts that require torque of 610 Nm(450 ft-lb). For dual wheels, the followingprocedure must be used.

1 Loosen nuts.

2 Tighten nuts to a torque of 610 Nm(450 ft-lb)

For stud and hub piloted wheel nuts: 610 —678 Nm (450 — 500 ft-lb)

For spoke wheels, check the manufacturer’sspecifications.

108 8. Body, Cab, and Interior Trim

SpecificationsCab Designations• VNL 780• VNL 670• VNL 630• VNL 430• VNL 300 (Daycab)

• VNM 630• VNM 430• VNM 200 (Daycab)• VHD 200B (Axle Back)• VHD 200F (Axle Forward)

L=long hood, M=medium hood

W8003128

8. Body, Cab, and Interior Trim 109

Seats

Tightening TorquesDriver’s Seat, Anchorage

Tightening torque, seat bracket......................... 48 ± 8 Nm (35 ± 5.9 ft-lb)

Safety Belts and Bunk Restraints

Safety belt D-ring, National and Isringhausenseats ...........................................................

50 ± 7 Nm (37 ± 5 ft-lb)

Retractor, National and Isringhausen seats.. 50 ± 7 Nm (37 ± 5 ft-lb)

ICP bar, National seats................................ 67 ± 7 Nm (50 ± 5 ft-lb)

Seat belt (seat frame), Isringhausen seat...... 50 ± 7 Nm (37 ± 5 ft-lb)

Bunk restraints, 7/16 in. screw.................... 68 ± 7 Nm (50 ± 5 ft-lb)

Bunk restraints, M8 screw.......................... 24 ± 4 Nm (18 ± 3 ft-lb)

110 8. Body, Cab, and Interior Trim

Climate Control Unit

SpecificationsGeneral

Refrigerant, type....................................... R134a (Tetraflourethane)

Air conditioning, volume ......................... 1400 g - day cabs1600 g - VN 430, 6301700 g - VN 670, 780

Compressor, marking............................... SD 7H15

No. of cylinders ........................................ 7

Cylinder volume ....................................... 155 cm³ (9.5 in³)

Compressor coupling............................... Electromagnetic

Lubricating oil capacity ........................... 300 cc (10.14 oz)

Pressure Monitor Switch PointsNote: Since the pressure transducer isdownstream of the compressor, gaugereadings could be .5 bar (7.3 psi) to 1.5 bar(21.8 psi) higher if the gauge is used at thecompressor discharge.

High pressure

opens at ............................................. 24 ± 2 bar (348 psi)

closes at ............................................. 20 ± 2 bar (290 psi)

Low pressure

opens at ............................................. 2.0 ± 0.2 bar (29 psi)

closes at ............................................. 2.1 ± 0.2 bar (30 psi)

Volvo Trucks North America, Inc.P.O. Box 26115 Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd.5600A Cancross Court, Mississauga, Ontario L5R 3E9

http://www.volvotrucks.volvo.com

PV776-20 003739 () 11.2004 © Volvo Trucks North America, Inc. , 2004

PV776-20 003739

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