Académique Documents
Professionnel Documents
Culture Documents
Quick-Reference Guide
VN, VHD VERSION2 dated
January 2003, Publication No.
PV776-20 182094
Quick-Reference Guide
VN, VHD VERSION2
December 2004
Foreword
This book is intended primarily for technicians, but also may be
helpful to others who need technical information about the vehicle
or related components.
Information has been compressed to accommodate the size
restrictions of this format. Therefore, always refer to the appropriate
technical service information for the most complete and current data.
Contents
0. General ............................................... 1
Tightening Torques, General ................. 1
Data Link Communication .................... 3
Vehicle Identification ........................... 14
1. Service and Maintenance ................ 16
Oil Change Volumes .............................. 16
2. Engine ...............................................
Specifications .........................................
General ................................................
Engine ..................................................
Valves ..................................................
Timing Gears and Camshaft ................
Lubrication and Oil Systems ...............
Fuel System .........................................
Intake and Exhaust System ..................
Cooling System ...................................
Engine Control System ........................
Tightening Torques and Patterns .........
19
19
19
21
23
28
37
39
40
47
50
55
74
74
74
75
77
5. Brakes ...............................................
Specifications .........................................
Drum Brake .........................................
Compressor ..........................................
Air Drier ..............................................
Brake Valves ........................................
80
80
80
82
86
89
97
97
97
98
101
101
101
106
108
108
108
109
110
0. General
Tightening Torques, General
Strength Classes 4.8, 5.8
4.8
5.8
Thread
Nm (ft-lb)
Thread
Nm (ft-lb)
M3
M5
M4
M6
6 1 (4.4 0.7)
M5
3 0.5 (2.2)
M8
M6
5 0.8 (3.6)
M10
M8
12 2 (8.8 1.4)
M12
50 8 (37 6)
M10
24 4 (18 3)
Low
None
Average
None
High
Application
Test
d = thread diameter
Thread
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
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)
M14
M16
M18
0. General
Thread
Average
High
M20
M22
M24
Thread
Average
High
M5
6 0.1 (4.4)
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)
M14
M16
M18
M20
M22
M24
0. General
Data Link Communication
Communication between the different Electronic Control
Units (ECUs) takes place via the two data links: the
J1939 control data link and the J1587/1708 information
data link.
The diagram below shows how the control units, the
diagnostic connector, and the instrument cluster are
connected in principle.
The instrument cluster, the Engine ECU (EECU),
vehicle ECU (VECU), Light Control Module (LCM)
and the diagnostic connector are always included in
the system. The system may include other control units,
depending on the vehicle type and optional equipment.
W3005654
0. General
Fault Codes
MID Message Identification Description
(identification of ECU)
PID
0. General
MIDs
MID 128
MID 130
MID 136
MID 140
MID 142
MID 144
MID 146
MID 216
MID 232
MID 249
MID 250
J19391
J19392
J19393
J19394
0. General
SID 21
SID 22
SID 33
SID 70
SID 71
SID 78
SID 146
SID 211
SID 230
SID 231
SID 232
SID 240
SID 253
SID 254
SID 266
SID 281
SID 282
PSID 201
PID 362
EGR valve 2
PID 245
PID 228
Ambient temperature
PID 175
Program memory
Battery voltage
PID 172
5 Volt DC supply
Crankcase pressure
PID 171
PID 158
PID 153
5 volt DC supply
Atmospheric pressure
PID 111
EGR valve 1
PID 110
PID 108
Preheater element 2
PID 105
Preheater element 1
PID 102
Fan control
PID 100
PID 98
PID 97
PID 94
SID 18
PID 91
EPG 1
Vehicle speed
PID 85
Preheater status
PID 84
PID 45
PPID 119
Fan speed %
PID 27
SID 1-6
PID 26
PPID 86
PPID 124
Component/Function
Component/Function
PPID 122
Fault
Code
Fault
Code
0. General
MID 136
Fault
Code
Component/Function
Fault
Code
Component/Function
SID 1
SID 10
SID 2
SID 11
SID 3
SID 12
SID 4
SID 13
SID 5
SID 14
SID 6
SID 15
SID 7
SID 18
SID 8
SID 19
SID 9
MID 140
Fault
code
Component / function
Fault
code
Component / function
PID 77
SID 240
Program memory
PID 78
SID 250
PID 96
Fuel level
SID 253
PID 116
PSID 7
PID 117
PSID 200
PID 118
PSID 201
PID 158
Battery voltage
PSID 204
PID 171
Ambient temperature
PID 177
PID 178
PID 179
SID 231
unit
PSID 210
PSID 232
0. General
MID 142
Fault
Code
Component/Function
Fault
Code
Component/Function
PID 155
Output 1-4
PSID 4
GPS module/interface
PID 155
Input 1-4
PSID 5
DSP module/interface
PID 154
Input 5-8
PSID 6
SID 240
Memory flash/RAM
PSID 8
SID 250
PSID 161
SID 253
Memory ROM
PSID 162
VIN mismatch
PSID 3
MID 144
Fault
code
Component
Fault
code
Component
PID 84
Vehicle speed
SID 231
PID 91
SID 240
Program memory
PID 150
SID 243
PID 152
SID 250
PID 191
SID 253
PPID 61
PSID 4
PPID 69
engine only)
PSID 200
Engine timeout
PPID 70
PSID 202
Instrument timeout
PPID 71
PSID 204
ABS/EBS timeout
PSID 210
LCM timeout
PSID 214
supply
PPID 72
PPID 74
SID 230
0. General
MID 146
Fault
code
Component / function
Fault
code
Component / function
PID 170
SID 14
PID 171
SID 15
SID 2
SID 16
SID 5
SID 17
SID 18
SID 19
SID 22
Recirculation
SID 6
SID 9
pressure side
compressor
SID 250
SID 12
PID 170
SID 13
SID 11
10
0. General
MID 216
Fault
code
Component / function
Fault
code
Component / function
SID 240
Program memory
PSID 34
Power supply 1
SID 250
PSID 35
Power supply 2
SID 253
PSID 36
Power supply 3
SID 254
Control unit
PSID 37
Power supply 4
PSID 1
PSID 38
Power supply 5
PSID 2
PSID 39
Power supply 6
PSID 3
PSID 40
PSID 4
PSID 5
Fog lights
PSID 7
Driving lights
PSID 8
Reverse lights
PSID 10
PSID 11
PSID 12
PSID 13
PSID 14
PSID 17
PSID 18
PSID 19
PSID 20
Dashboard dimming
PSID 27
PSID 28
PSID 29
PSID 30
PSID 33
position
PSID 41
PSID 42
PSID 45
PSID 46
PSID 48
PSID 49
PSID 50
PSID 51
PSID 52
PSID 53
PSID 54
Marker interrupt
PSID 55
Headlamp interrupt
PSID 57
PSID 200
PSID 201
0. General
11
MID 232
Fault
Code
Component/Function
Fault
Code
Component/Function
SID 1
SID 254
SID 240
Program memory
PSID 1
SID 253
Calibration memory
PSID 2
No VIN response
Fault
Code
Component/Function
Fault
Code
Component/Function
PID 29
PSID 201
MID 249
position
SID 230
Idle switch
SID 231
SID 253
PSID 200
vehicle ECU
PSID 202
engine ECU
MID 250
Fault
Code
Component/Function
Fault
Code
Component/Function
SID 231
PSID 6
Volume (-)
SID 251
PSID 9
Headlamp interrupt
PSID 10
Marker interrupt
PSID 17
functions (SWM)
SID 254
PSID 3
Arrow left
PSID 4
Arrow right
PSID 5
Volume (+)
buttons
PSID 18
12
0. General
FMI Table
FMI
Display Text
Faulty data
Electrical fault
Electrical fault
Electrical fault
Electrical fault
Mechanical faults
Mechanical or electrical
fault
Abnormal frequency
Communication fault
10
Mechanical or electrical
fault
11
Unknown fault
Unidentifiable fault
12
Component fault
13
Faulty calibration
14
Unknown fault
Special instructions.
15
Unknown fault
0. General
13
Diagnostic Connector
W3005648
Circuit Description
0Z (B-)
402 (B+)
not used
not used
196DR (Ignition)
14
0. General
Vehicle Identification
Labels
It is extremely important that the correct vehicle model
and Vehicle Identification Number (VIN) are given
whenever replacement parts or service literature 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.
Manufacturing location
Engine type
Check sum figure
Assembly factory
Type of cab
Brakes / axle combination
Model year
Chassis number
Certification Label
W8003115
0. General
15
Chassis Number
The 8-digit chassis number is embossed
into the frame rail at two locations: the
bottom flange right-hand side, and the top
flange left-hand side of the frame rail. These
numbers are set 1065 mm (42 in.) back from
the front edge of the frame rail.
W0001995
Engine
The Volvo D12D engine serial number is
located on the rear, left side of the cylinder
block.
The serial number can also be found on the
certification label on the valve cover.
W2003921
Rear Axle
The axle model and serial number is located
on the front left side of the forward drive
axle and the front right side of the rear drive
axle. It is also located on the front right side
of the single axle.
W4002560
Transmission
16
Engine
Approximate oil change capacity
Normal oil
change (incl.
filter)
Dry capacity
Max. to Min.
on dipstick
D12D
33 L
(35 qts)
37 L
(39 qts)
8L
(8.5 qts)
D12D
38 L
(40 qts)
42 L
(44 qts)
6L
(6.5 qts)
Vehicle
Engine
VN
VHD
Power Take-off
Model
flywheel-mounted
17
Rear Axle
Model
Each hub
Total
RSS1344B
8.5 L (9 qt)
8.5 L (9 qt)
9 L (9.5 qt)
9 L (9.5 qt)
19 L (20.1 qt)
22 L (23.2 qt)
20 L (21.1 qt)
3 L (3.2 qt)
26 L (27.5 qt)
16 L (16.9 qt)
3 L (3.2 qt)
22 L (23.2 qt)
RS1365HV
RS1352HV
22 L (23.2 qt)
3 L (3.2 qt)
28 L (29.6 qt)
19 L (20.1 qt)
22 L (23.2 qt)
20 L (21.1 qt)
3 L (3.2 qt)
26 L (27.5 qt)
16 L (16.9 qt)
3 L (3.2 qt)
22 L (23.2 qt)
20 L (21.1 qt)
20 L (21.1 qt)
9 L (9.5 qt)
9 L (9.5 qt)
16 L (16.9 qt)
16 L (16.9 qt)
23 L (24.3 qt)
3 L (3.2 qt)
30 L (31.2 qt)
19 L (20.1 qt)
3 L (3.2 qt)
26 L (27.5 qt)
23 L (24.3 qt)
3 L (3.2 qt)
29 L (30.6 qt)
19 L (20.1 qt)
3 L (3.2 qt)
25 L (26.4 qt)
3 L (3.2 qt)
28 L (29.6 qt)
3 L (3.2 qt)
24 L (25.3 qt)
23 L (24.3 qt)
3 L (3.2 qt)
30 L (31.7 qt)
19 L (20.1 qt)
3 L (3.2 qt)
26 L (27.5 qt)
RS1370HV
The oil volume is only 1.5 liter for hub reduction housings with part numbers 1524851 or 1524852. These
markings can be seen on the hub reduction housings.
18
FS0910HZ
Transfer Case
Model
VT2501TB
Hydraulic Retarder
Model
RET-TH
2. Engine
19
Specifications
General
Power Output 1
D12D 365
D12D 425
D12D 435
D12D 465
D12D 395
Torque 2
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.
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
Cylinder diameter
Stroke
Displacement
Firing sequence
1-5-3-6-2-4
Compression ratio
17.3:1
max 20%
Low idle
High idle
Max length
Max width
Max height
2. Engine
21
Engine
Cylinder
Cylinder Head
Type
6 cylinder
Length
Width
Height
38
Thread size
M16
Length
Cylinder Block
Length
Cylinder Liner
Type
Wet, replaceable
Height, total
1+3
22
2. Engine
Piston
Type
steel
89 mm (3.50 in.)
Front marking
55 mm (2.17 in.)
Piston Rings
Compression rings
Specification
Wear tolerance
Number
Specification
Wear tolerance
Number
4.32 mm
(0.170 in.)
0.05 - 0.10 mm
(0.0019 - 0.0039 in.)
0.35 - 0.65 mm
(0.0137 - 0.0260 in.)
< 1.0 mm
(0.039 in.)
2. Engine
23
Valves
Valve disc, diameter:
Intake
40 mm (1.6 in.)
Exhaust
40 mm (1.6 in.)
8 mm (0.315 in.)
Exhaust
8 mm (0.315 in.)
29.5
Exhaust
44.5
30
Exhaust
45
T2019432
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.)
24
2. Engine
Exhaust
Exhaust, VEB
0.15 - 0.25 mm
Exhaust
0.45 - 0.55 mm
Exhaust, VEB
1.55 - 1.65 mm
Valve Seats
Outer diameter (A)
Standard:
Intake
Exhaust
Oversize:
Intake
Exhaust
Height (B):
Intake
Exhaust
2. Engine
Valve Seat Location
Diameter (C) standard:
Intake
Exhaust
Exhaust
Depth (D) :
Intake
Exhaust
Exhaust, maximum
25
26
2. Engine
Valve Guides
Specification
Wear tolerance
83.4 mm
(3.283 in.)
83.4 mm
(3.283 in.)
8 mm
(0.315 in.)
8 mm
(0.315 in.)
26.5 0.4 mm
(1.043 0.016 in.)
26.5 0.4 mm
(1.043 0.016 in.)
Length:
Intake
Exhaust
Inner diameter:
Intake
Exhaust
Height above the cylinder head spring plate:
Intake
Exhaust
Clearance, valve stem - guide:
Intake
Exhaust
1
Measurements are calculated for the method described in Service Information, group 21.
2. Engine
Valve Springs
Intake (left-hand coil)
Length (unloaded)
58 mm (2.28 in.)
45 mm (1.77 in.)
40 mm (1.57 in.)
Exhaust
Outer valve spring (left-hand coil):
Length (unloaded)
58 mm (2.28 in.)
45 mm (1.77 in.)
40 mm (1.57 in.)
54 mm (2.13 in.)
41 mm (1.61 in.)
37 mm (1.46 in.)
Rocker Arms
Bearing play, maximum
27
28
2. Engine
0.05 - 0.17 mm
(0.002 - 0.007 in.)
99.99 0.01 mm
(3.937 0.0004 in.)
100.04 0.01 mm
(3.939 0.0004 in.)
max 0.07 mm
(0.003 in.)
max 0.17 mm
(0.007 in.)
2. Engine
C2001718
Number of teeth:
1
38
83
27
29
76
97
23
27
Intermediate gear
71
10
39
11
23
12
44
29
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.
Specification
Wear tolerance
Drive
Gear
Number of bearings
69.97-70.00 mm
(2.754 - 2.760 in.)
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.)
0.05 mm (0.0019
in.)
0.05 mm (0.0019
in.)
Valve lift:
Intake
Exhaust (VEB)
Exhaust (EPG)
2. Engine
31
Oversize:
0.25
0.50
0.75
Crankshaft
Length
32
2. Engine
Undersize:
0.25 mm (0.01 in.)
Ra 0.25
Ra 0.4
Oversize:
0.2 mm (0.008 in.), axial bearing 0.1 mm
(0.004 in.)
2. Engine
Oversize:
0.25 mm (0.01 in.)
Oversize:
0.1 mm
0.2 mm
0.3 mm
33
34
2. Engine
Connecting Rods
T2019085
T2012874
55 mm (2.165 in.)
1
2. Engine
Undersize:
0.25 mm (0.01 in.)
Ra 0.25
Ra 0.4
Width (A)
35
36
2. Engine
Oversize:
0.25 mm (0.01 in.)
Flywheel
Axial run-out (manual gearbox) measurement radius 150 mm
(5.91 in.), maximum
153
3 x 18
2. Engine
37
Activated VEB
Oil Temperature
Warm engine (running); coolant temperature 75 - 95
(167 - 203 F)
1
C
65 - 105
C (149 - 221
F) 1
Oil Pump
Type
Gear driven
Number of teeth:
Drive gear
23
Intermediate gear
44
Diameter:
Hub, intermediate gear
Axial clearance:
Drive gear, pump
Intermediate gear
Backlash
38
2. Engine
Oil Filter
Number
Full-flow filter (is tightened 1/2 - 3/4 turn after contact)
Oil Valves
T2012843
1. Safety valve
Marking
Yellow
124
69 mm (2.72 in.)
With a load of 13 - 15 Nm
40 mm (1.57 in.)
Orange
6. Reduction valve
Marking
Blue
2. Engine
39
Fuel System
Fuel Pump
Fuel pressure at:
600 rpm
1400 rpm
full load
Overflow Valve
Opening pressure
Unit Injector
T2012878
Tighten the adjustment screw to zero clearance on the camshaft, then turn an
additional 3 - 4 flats (180 240).
Cylinder Balancing
Cylinder balancing, VCADS
Compensation, maximum
80%
40
2. Engine
2. Engine
41
Response Values2
1200 rpm
2.57 V
1400 rpm
3.12 V
1600 rpm
3.21 V
1800 rpm
3.25 V
1200 rpm
2.73 V
1400 rpm
3.18 V
1600 rpm
3.26 V
1800 rpm
3.32 V
1200 rpm
2.88 V
1400 rpm
3.23 V
1600 rpm
3.32 V
1800 rpm
3.39 V
1200 rpm
2.88 V
1400 rpm
3.29 V
4 - 5 sec
1600 rpm
3.46 V
1800 rpm
3.47 V
1200 rpm
3.12 V
4 - 5 sec
1400 rpm
3.47 V
1600 rpm
3.67 V
1800 rpm
3.69 V
D12D365:
D12D395:
D12D425:
D12D435:
D12D465:
Test run with normal diesel fuel (type 2) and below 1500 m (4500 ft.) altitude.
Response times from 0 kPa (0 psi) charge air pressure to 90% of max charge air pressure.
42
2. Engine
Ambient temperature
10 - 30 C (50 - 86 F) above
ambient temperature
T2013094
29 mm (1.14 in.)
2. Engine
43
< 70 80
C/ 4
(158 176
F / 2
Engine load
Accelerator pedal
at rest (released)
Accelerator pedal
1
> 70
C (158
F)
Engine load could be more or less depending on engine speed. Check should be made with engine at idle speed.
44
2. Engine
Activation:
Coolant temperature
Clutch pedal
at rest (released)
Accelerator pedal
at rest (released)
Engine speed
idle
Ambient temperature
>4
EGR temperature
1
> 65
> 98
C (> 149
C ( > 25
C ( > 208
F)
F)
F) 1
Idle EGR is active when all conditions listed are met. After the first 3 minutes of idle time, the EMS reads
the 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 Brake
EPG Inlet Pressure
Note: Checks should be made with oil
temperature greater than 55 C (131 F)
T0008637
Braking force in % 1
Pressure of EPG in kPa (psi)
Exhaust brake
only
100% (high)
750 kPa (109 psi)
Engine brake,
switch position 1
1
Cruise mode
50 - 750 kPa (7 - 109 psi)
T0008058
VEB
Brake force in % 1
Pressure of EPG in kPa (psi)
EPG VCB
50% (low)
750 kPa
(109 psi)
50 750 kPa
(7 109 psi)
On
Off
VEB switch
position 2
2
Cruise mode 2
VEB Switch
position 1
100% (high)
750 kPa
(109 psi)
750 kPa
(109 psi)
50 750 kPa
(7 109 psi)
On
On
3way switch can give 50% (low) or 100% (high) EPG and VCB
Cruise control overspeed protection. Engine brake activation. parameter AF in VECU MID 144
46
2. Engine
EPG
Activated:
engine speed
vehicle speed
Deactivated:
engine speed
vehicle speed
VCB
Activated:
engine speed 1
vehicle speed
> 55
C (131
F) 2
> 60
C (140
F) 3
Deactivated:
engine speed1
vehicle speed
< 55
C (131
F)
The value is increased to 1400 rpm for the first five activations. Applies at engine oil temperatures 55 82 C (131 - 180 F).
Oil temperature sensor combined with oil pressure sensor
Oil temperature sensor combined with oil level sensor in oil pan
2. Engine
Exhaust Backpressure
Standard muffler, maximum
Oct. 02 - Jan. 04
Cooling System
For cooling system volumes and coolant requirements,
refer to Service Information, group 18: Coolant
Requirements, Volvo Engines.
General
Pressure valve opens at
75 kPa
(10.9 psi)
Fan
Viscous Fan (Air Sensing Fan)
Speed, engaged (engine speed @ 1800 rpm)
Fan pulley diameter 167 mm (6.57 in.)
2400 rpm
2150 rpm
1900 rpm
Engagement temperature
75
C (167
F) in front of fan
47
48
2. Engine
Condition
Coolant temperature
Start temperature 90
(194 F)
Coolant temperature
> 93
1200 rpm
AC system
1200 rpm
1000 rpm
1200 rpm
600 rpm
C (199F)
600 rpm
Variable fan speed activation
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
F)
AC system
Thermostat
Quantity
Opening temperature
82
C (179
F)
C (196
F), deactivation 87
C (212
C (189
50
2. Engine
2 x 62
Sensors
Charge air sensor
Check value
T2019008
2. Engine
T2019009
51
52
2. Engine
T2019010
2. Engine
T2019011
Camshaft sensor
Distance to
camshaft
Resistance
measurement
775 - 945
Flywheel sensor
Distance to
flywheel
Resistance
measurement
775 - 945
53
54
2. Engine
Crankcase
pressure: normal
value (VEB not
active) regardless
of engine speed,
maximum
2. Engine
55
24 4 Nm (18 3 ft-lb)
48 8 Nm (35 6 ft-lb)
85 15 Nm (63 11 ft-lb)
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 damage
under the head) must be replaced.
56
2. Engine
Group 21
Tightening:
Torque
175 20 Nm (129 15
ft-lb
85 15 Nm (63 11
ft-lb)
Angle
245 35 Nm (181 27
ft-lb)
175 5 Nm (129 4
ft-lb)
step 2
255 38 Nm (188 28
ft-lb)
150 20 Nm (110 15
ft-lb)
step 2
120 5
275 15 Nm (204 11
ft-lb)
2. Engine
T2014149
Tightening:
Torque
Angle
Stiffening frame
step 1: tighten screws 1-6 in sequence
48 8 Nm (36 6 ft-lb)
15 Nm (11 ft-lb)
24 4 Nm (18 3 ft-lb)
90 5
57
58
2. Engine
T2006973
Tightening:
Torque
Angle
60 5 Nm (44 4 ft-lb)
60 5
2. Engine
T2019062
Tightening:
Torque
Flywheel housing
140 14 Nm (105 10
ft-lb)
Angle
59
60
2. Engine
T2014027
Vibration damper, VN
tightening sequence.
Tightening:
W2004219
Torque
Angle
Vibration damper
step 1 1 .......................................................
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
Torque
40 3 Nm (29 2 ft-lb)
62
2. Engine
T2007004
Tightening:
Torque
Angle
60 10 Nm (44 7 ft-lb)
60 10 Nm (44 7 ft-lb)
step 3
90 5
90 5
60 10 Nm (44 7 ft-lb)
38 4 Nm (28 3 ft-lb)
60 5
after contact
60 5
after contact
60 +10/-0
after contact
2. Engine
T2012850
Tightening:
Torque
Angle
15 5 Nm (11 4 ft-lb)
90 5
step 3
60 5 Nm (44 4 ft-lb)
15 5 Nm (11 4 ft-lb)
120 5
15 5 Nm (11 4 ft-lb)
120 5
Screws must be tightened in stages to ensure that the rocker arm shaft comes down without bending.
63
64
2. Engine
T2019046
Tightening:
Torque
34 4 Nm (24 3 ft-lb)
2. Engine
T2019925
Tightening:
Torque
24 4 Nm (18 3 ft-lb)
48 8 Nm (36 6 ft-lb)
Thickness 2 mm.
65
66
2. Engine
W2004477
Gear train
Tightening:
Torque
Angle
A.
Camshaft gear
35 3 Nm (26 2 ft-lb)
90 5
B.
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.
645 25 Nm (476 18
ft-lb)
F.
Idler gear
15 3 Nm (11 2 ft-lb)
120 5
2. Engine
Group 22
T2017885
Tightening:
Torque
24 3 Nm (18 2 ft-lb)
60 10 Nm (44 7 ft-lb)
24 3 Nm (18 2 ft-lb)
27 3 Nm (20 2 ft-lb)
27 3 Nm (20 2 ft-lb)
67
68
2. Engine
T2006825
T2006701
Delivery pipe
Delivery Pipe
Torque
Angle
Step 1:
Tighten fitting in cylinder block until it
bottoms; approximately
10 Nm (88 in-lb)
Step 2:
New pipe
180
60
2. Engine
T2014088
Oil cooler, cover; always use guide pins when installing the cover on the
engine.
Tightening:
Torque
24 4 Nm (18 3 ft-lb)
Tighten C and D
24 4 Nm (18 3 ft-lb)
24 4 Nm (18 3 ft-lb)
24 4 Nm (18 3 ft-lb)
69
70
2. Engine
Group 23
Tightening:
Torque
Angle
20 5 Nm (15 4 ft-lb)
step 2
180 5
20 5 Nm (15 4 ft-lb)
step 2
60 5
20 5 Nm (15 4 ft-lb)
step 2
60 5
52 4 Nm (38 3 ft-lb)
Option 2
45 5
Banjo screw, 10 mm
12 2 Nm (108 22
inch-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
Group 25
W2004483
Exhaust manifold
Torque
1.
10 Nm (88 inch-lb)
2.
10 Nm (88 inch-lb)
3.
Tighten bolts 3 to
52 4 Nm (38 3 ft-lb)
4.
Tighten bolts 2 to
52 4 Nm (38 3 ft-lb)
5.
Tighten bolts 4 to
52 4 Nm (38 3 ft-lb)
6.
Tighten bolts 1 to
52 4 Nm (38 3 ft-lb)
Tightening
Torque
10 1 Nm (71 8 inch-lb)
20 3 Nm (15 2 ft-lb)
71
72
2. Engine
EGR System
W2004292
Tightening
Torque
EGR Pipes:
V-clamp
10 2 Nm (88 17 inch-lb)
5 1 Nm (35 9 inch-lb)
15 3 Nm (133 3 inch-lb)
Vibration Damper
24 4 Nm (18 3 ft-lb)
2. Engine
73
W2004261
Tightening Sequence
Torque
24 4 Nm (18 3 ft-lb)
2.
Screw/lock nut
12 2 Nm (106 17 inch-lb)
Screw/lock nut
12 2 Nm (106 17 inch-lb)
Group 26
Thermostat, mounting bolts
Torque
24 4 Nm (18 3 ft-lb)
30 4 Nm (22 3 ft-lb)
74
Specifications
Fuse and Relay Locations
The vehicles instrumentation, gauges and
other electrically controlled parts are wired
through 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, one
located in the middle of the dash under the
top cover, and the other under the front
cover. The electrical center underneath the
front cover is the power module and it feeds
the relays to the electrical center under the
top cover.
Located just below the fuse/relay panel
are the following modules: Vehicle
ECU/Bodybuilder module, Light Control
Module, Steering Wheel Module and Central
Locking Module/relay.
Refer to the decal inside the TEC cover for
vehicles exact fuse locations and ratings.
(Note that all fuses and relays may not be
used in every vehicle.)
The TEC panel includes all maxi-fuses,
mini-fuses, relays and micro-relays.
Maxi-fuses are designed for larger amounts
of current than regular fuses. The micro ISO
relays are smaller in size than conventional
relays, and the pin arrangement is different.
Mini-fuses are also smaller in size, but the
current rating is the same as ATO-size fuses.
W3005285
Delco 42MT
1
2
3
4
5
Solenoid
Shift Lever
Housing
Nose Housing
Pinion
Overcrank
Protection Input
Connector
1
2
3
Delco 39 MT HD
Solenoid
Heavy-duty Relay
Pinion
Starter
solenoid
stud 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)
Starter
ground
stud
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)
Battery
cables (+
and -)
19 1Nm
(14 1 ft-lb)
Main
power
studs (at
cab passthrough)
10 2 Nm
(88 17 in-lb)
Main
ground
studs (at
cab passthrough)
10 2 Nm
(88 17 in-lb)
75
76
Torque Specification
10 2 Nm (89 18 in-lb)
Engine Block
Engine block ground
Starter Motor
Main power and ground
Alternator (33SI/34SI)
Battery terminal circuit 8
I terminal circuit 14
R terminal circuit 16
Alternator (22SI)
Battery terminal circuit 8
I terminal circuit 14
R terminal circuit 16
Preheater Relay)
Power stud
Coil stud
Preheater Assembly
Brass Nut
Flange screw
Bulkhead
Engine-side ground studs
6 1 Nm (53 8 in-lb)
Starter relay
Power stud
77
W3005269
T3014623
78
Light Switch
W3005328
1. Light Switch
2. Hazard Warning lights
switch/Hazard warning lights
indicator light
3. Rheostat for instrument lighting
A. Off
B. Park
C. Drive
D. Drive+
Note: Only premium version have
the Drive+ position.
79
W3005328
Terminal
1
Function
2
Open
Parking lights
(B)
Headlights (C)
Open
Open
Headlights with
auxillary lights
(D)
Open
0ff (A)
80
5. Brakes
Specifications
Drum Brake
Brake Slack Adjusters and Cam
W5001492
DANGER
Before checking the slack adjusters, set
the parking brakes, place the transmission
in neutral, and block the wheels. Failure
to do so can result in unexpected vehicle
movement and can cause serious personal
injury of death.
To check the slack adjusters for proper throw,
use a breaker bar to lever the slack adjuster
out. Measure the distance of the travel. It
should not exceed 25 30 mm (1 1.25 in)
for a 6 inch slack adjuster and should not
exceed 20 25 mm (.75 1 in) for a 5.5
inch slack adjuster. Also make sure that the
length of the slack adjuster is the same on
an axle.
Note: Travel is measured from the chamber
face as shown in the illustration.
5. Brakes
81
Brake Linings
DANGER
Before measuring linings, set the parking
brakes, place the transmission in neutral,
and block the wheels. Failure to do so can
result in unexpected vehicle movement
and can cause serious personal injury of
death.
W7001278
82
5. Brakes
Compressor
1COMP530
T5012037
Model ........................................................................
WABCO 352
20382348
Type ..........................................................................
Piston compressor
Fluid
Air
440 dm/min
3000 rpm
85 mm (3.34 in.)
Stroke ........................................................................
62 mm (2.44 in.)
PR function:
Cylinder stroke PR-piston reed valve .......................
5. Brakes
Tightening Torques
Tightening:
Torque - Nm (ft-lb)
25 4 (18 2.9)
25 2 (18 1.4)
90
10 1 (7.3 .7)
90
25 4 (18 2.9)
T5012871
Angle
83
84
5. Brakes
2COM1080 VERSION2
T5012038
Make .........................................................................
WABCO 704
20382347
Type ..........................................................................
Piston compressor
Fluid
Air
800 dm/min
3000 rpm
85 mm (3.34 in)
Stroke ........................................................................
62 mm (2.44 in)
PR function:
Cylinder stroke PR-piston reed valve .......................
5. Brakes
Tightening Torques
Tightening:
Torque - Nm (ft-lb)
Angle
25 4 (18 2.95)
25 2 (18 1.47)
90
7 2 (5 1.47)
90
25 4 (18 2.95)
85 15 (62 11)
T5012835
85
86
5. Brakes
Air Drier
Wabco SS1200P
Height
Voltage .....................
12 V
Maximum flow
capacity ...................
100 W
Voltage .....................
12 V
Maximum flow
capacity ...................
100 W
Bendix ADIP
Height .......................
Weight ......................
13 kg (28 lb)
Voltage .....................
12 V
Maximum flow
capacity ....................
90 W
5. Brakes
Bendix AD-9
Height .......................
Weight ......................
13 kg (28 lb)
Voltage .....................
12 V or 24 V
Maximum flow
capacity ....................
90 W
Weight ......................
8 kg (18 lb)
Voltage .....................
12 V
Maximum flow
capacity ....................
95 W
87
88
5. Brakes
CR Turbo 2000
Height .......................
Weight ......................
Voltage .....................
12 V
Maximum flow
capacity ....................
75 W
5. Brakes
Brake Valves
Treadle Valve
Main brake actuation valve, foot operated.
Make, Model
Bendix, E6
Meritor Wabco
89
90
5. Brakes
Meritor Wabco
Meritor Wabco
Pressure delivery
5. Brakes
Quick Release Valve
For rapid release of brake application air on
the front wheels.
Make
Meritor Wabco
Crack pressure
Connections
Supply port
1/2 NPTF
Delivery port
3/8 NPTF
Meritor Wabco
Connections
Supply port
1/4 NPTF
Anti-compounding port
1/4 NPTF
Delivery port
3/8 NPTF
91
92
5. Brakes
Meritor Wabco
Port
Connection
1/2 PTC
3/8 NPTF
1/2 PTC
3/8 PTC
3/8 PTC
5. Brakes
Tractor Protection Valve
Used on trucks intended to pull a trailer.
Protects system air pressure on the towing
vehicle in the event of a trailer breakaway.
Make
Meritor Wabco
Port
Connection
1/2 PTC
3/8 PTC
3/8 PTC
1/4 PTC
1/2 NPTF
1/2 NPTF
Air Governor
Make
Meritor Wabco
Max. operating
pressure
150 psi
Cut-in pressure
110 psi
Cut-out pressure
130 psi
All ports
1/8 NPTF
93
94
5. Brakes
Meritor Wabco
Crack pressure
Port
Connection
Control port
1/4 NPTF
Supply port
1/2 NPTF
1/2 NPTF
Safety Valve
Over pressurization protection mounted in
the wet tank.
Make
Meritor Wabco
5. Brakes
Pressure Protection Valve Manifold
Frame mounted valve with multiple delivery
ports. Purpose is to supply air to all
non-brake related systems. Protects the main
brake air by disallowing pressure loss in the
main air system lower than 70 psi in the event
of a non brake related system failure/leak.
Port
Connection
Control port
Meritor Wabco
Supply port
Opening pressure
Closing pressure
Port
Connection
Supply port
1/2 PTC
1/4 PTC
3/8 PTC
95
96
5. Brakes
W5001392
AP-TD
REAR SUP
SLS
FRT SUP
PBS
B-TD
B tank, transducer
PARK
A-TD
A tank transducer
B-Tank
10
A-Tank
11
97
Specifications
Wheel Alignment
The following alignment specifications represent the
industry standard established for a mid point target value
on wheel alignment. Setting alignment for the target value
minimizes inherent variations in measurement systems
and provides optimum tire life. All values given in the
table are for unladen vehicles with no trailer connected.
Note: Actual measurement can vary and still meet
factory specifications. Contact the original equipment
manufacturer for specification questions.
Steer Axle:
Toe-In ........................................................................
Camber ......................................................................
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.
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 axle
manufacturers warranty. If the measurement exceeds this value consult the vehicle, axle,
and/or alignment equipment manufacturer.
98
Steering
Steering Wheel/Adjustment, Steering Column
Clearance in steering wheel universal joints, lower
steering column 1 ........................................................
Elasticity/slack in lower steering column, steering column
in working position and turned with 10 Nm ..............
1.2
1
Zero slack
5 mm (0.19 in.)
When the steering column is pulled out, outside the ordinary driving position, slack is permissible
TRW TAS-65
Sheppard
M100
TRW 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 wheel
travel
4.5 turns
4.75 turns
4.75 turns
4.75 turns
Max. output
torque
43,050 in-lb (@
2175 psi)
43,050 in-lb (@
2175 psi)
43,6000 in-lb
(@2682 psi)
58,850 in-lb (@
2175 psi)
VOLVO D12
Rotation
Drive type
Displacement /rev (cm3)
cw
gear
18 (VN)
18-25 (VHD)
cw
spline
22-25 (VN)
22-36 (VHD)
Oil type
Regulated Flow
System
VHD
VN
Oil capacity
99
100
Tightening Torques
Steering Wheel
Steering wheel center bolt
85 15 Nm (63 11 ft-lb)
Steering Column
Upper steering column attachment
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
45 5 Nm (33 4 ft-lb)
Mounting bolts
46 1 Nm (34 1 ft-lb)
101
Specifications
Suspension
Location
Diameter
Grade
Torque
M20
M20
M20
M16
M20
M20
M24
M22
M20
M24
M16
8.8
M12
10.9
M12
8.8
M16
10.9
M16
10.9
M14
10.9
M16
8.8
M14
10.9
46,000 lbs.)
102
Diameter
Grade
M6
8.8
10 1.5 Nm (7 1 ft-lb)
M14
10.9
Torque
103
Pinion Angle
(Drive axle 1)
Pinion Angle
(Drive axle 2)
Meritor RT40-145
266 (10.47)
2.5 1
13.0 1
RRH 200
2.5 1
11.5 1
300 (11.81)
203 5 (8 0.2)
2.5 1
13.0 1
RRH 180
203 5 (8 0.2)
2.5 1
11.5 1
266 (10.47)
2.5 1
13.0 1
RRH 160
1.8 1
12.2 1
266 (10.47)
2.5 1
12.0 1
RRH 200
2.5 1
10.5 1
300 (11.81)
203 5 (8 0.2)
2.5 1
12.0 1
RRH 180
203 5 (8 0.2)
2.5 1
10.5 1
266 (10.47)
1.8 1
11.3 1
RRH 160
1.6 1
11.1 1
266
2.5 1
8.0 1
RRH 200
2.5 1
2.5 1
300
203 5 (8 0.2)
2.5 1
8.0 1
RRH 180
203 5 (8 0.2)
2.5 1
2.5 1
Dana 404
DST 40
Meritor MT4014M
266
2.5 1
2.5 1
RRH 200
2.5 1
2.5 1
300
203 5 (8 0.2)
2.5 1
2.5 1
RRH 180
203 5 (8 0.2)
2.5 1
2.5 1
104
Pinion Angle
(Drive axle 1)
Pinion Angle
(Drive axle 2)
3.5 1
105
Suspension Applications
Note: There are different vehicle suspension ride height
(RRH) versions. RRH-180 and RRH-220 has a stamped
sheet metal torque rod bracket with Meritor RT-40-145
axles. All other axles have cast iron torque rod brackets.
RRH-160 has always had cast iron torque rod brackets.
Suspension Configuration
Maximum
GAWR
Metric Ton
(lb)
4x2
9 (20,000)
17
(38,000)
6x4
18
(40,000)
18
(40,000)
Maximum
GCW
Metric Ton
(lb)
Required
Number of
Parking
Chambers
N/A
50
(110,000)
(1)
Axle
Spacing
mm (in.)
TWO
1320 (52)
TWO (1st
Axle)
1320 (52)
FOUR
1524 (60)
Available Axles
FOUR
Models
Metric Ton
(lb)
Eaton
Meritor
10
(23,000)
Eaton
Meritor
18
(40,000)
(1) GCW (Gross Combination Weight) rating can be reduced by vehicle operating
applications, engine horsepower/torque, axle type/model, axle ratio, and/or vehicle tire size.
106
Wheels
Drive Axle Shaft Nuts, Tightening Torque
Fastener
Torque Values
Fastener
Torque Values
Thread
Size (in.)
Lock Nut
Thread
Size (in.)
Lock Nut
0.75 - 16
372 34 Nm
(275 25 ft-lb)
M14 x 2
150 15 Nm
(110 10 ft-lb)
Fastener
Torque Values
Thread
Size (in.)
Lock Nut
5/8
135 20 Nm
(100 15 ft-lb)
W7000774
Tightening sequence
Loosen nuts.
107
108
Specifications
Cab 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)
W8003128
50 7 Nm (37 5 ft-lb)
50 7 Nm (37 5 ft-lb)
67 7 Nm (50 5 ft-lb)
50 7 Nm (37 5 ft-lb)
68 7 Nm (50 5 ft-lb)
24 4 Nm (18 3 ft-lb)
109
110
R134a (Tetraflourethane)
SD 7H15
Electromagnetic
opens at .............................................
closes at .............................................
Low pressure
opens at .............................................
closes at .............................................