Volvo Truck Service Schedule Maintenace 1

Volvo Trucks and Prime movers - Periodic Maintenance Training
1.Road Test/Check Warning & Control Lamps Basic Annual

Service Schedule Based on Kilometers (Kms.) 20000/40000/60000/80000 100000
Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000
Road Test
1 Check Warning and Control Lamps
2 Check seat belt
3 Check after start
4 Check during road test
5 Check after road test
6 Connect-disconnect PC
7 Check height regulation for air suspension
1. Information display: clock, outside

temperature, trip meter, odometer, fuel
gauge, AdBlue gauge, coolant temperature
2. Exterior light indicators
3. Direction indicators
4. Speedometer
5. Centre display: cruise control, gear and
auxiliary brake information
6. Control and warning lamps
7. Driver information display
8. Engine related indicators
9. Tachometer
10. Bogie and differential indicators
11. Control for trip meter* *A brief press on
the control switches (11) between trip
meter T1 and T2. A long press resets the
active trip meter.
2.Road Test/Check Seat Belt Basic Annual
Road Test
1 Check Warning and Control Lamps Check Locking Check Warning Light
2 Check seat belt
3 Check after start

4. Speedometer
9. Tachometer
the control switches (11) between trip Check Seat Belt Release Check Seat Belt Condition
active trip meter.
3.Road Test/Check After Start Basic Annual
Road Test • Check that the longitudinal position and the height of the steering wheel can be adjusted. Check
1 Check Warning and Control Lamps that the steering wheel is locked in the adjusted position.
2 Check seat belt • Check that all of the control and warning lamps, and the instruments, are working.
• The oil pressure, alternator charging and OBD warning lamps should go out as soon as the engine is
3 Check after start
started.
4 Check during road test • Check that the engine oil pressure gauge shows oil pressure.
5 Check after road test • The symbol or the warning lamp which indicates that the coolant is low must switch off.
6 Connect-disconnect PC • The symbol or warning lamp that indicates that the cab is locked must be switched off, which
7 Check height regulation for air suspension indicates that the cab is properly locked.
• The power steering system warning lamp for the pusher and trailing axle must be switched off.
• The service brake warning lamps must switch off when the compressed air system is charged.
• The parking brake warning lamp must light up when the parking brake is applied.
• The ABS brake control lamp must light up.
Checking the centering function of the hydraulically-driven pusher or trailing axle.
1. Information display: clock, outside 1. Turn the wheels to one side (the front axle wheels, the pusher axle wheels or the trailing axle
temperature, trip meter, odometer, fuel wheels).
2. Switch off the engine.
3. Direction indicators 3. Turn the ignition key to the start position and at the same time check that the pusher axle wheels
4. Speedometer or the trailing axle wheels make a centering movement.
5. Centre display: cruise control, gear and 4. When the front axle wheels are turned towards the straight line position, the pusher axle wheels or
auxiliary brake information the trailing axle wheels will start to turn in the other direction. When the front axle wheels are
close to the straight line position, the pusher axle wheels or the trailing axle wheels will be
8. Engine related indicators centered. After this, the steering lock on both axles will be tracked from one to the other.
9. Tachometer
active trip meter.
4.Road Test/Check during road test Basic Annual
Road Test Note: During the road test, the driver should wear a safety belt, making sure that the AdBlue tank is
1 Check Warning and Control Lamps filled and that there is sufficient fuel.
2 Check seat belt
• Check that the speedometer/tachograph, the odometer and the other instruments are working.
3 Check after start
• The brake system pressure gauges must be displaying values which lie inside the normal range.
4 Check during road test • Check that the steering works satisfactorily and is not unbalanced.
5 Check after road test • Check that the brakes work correctly and do not pull to one side or lock.
6 Connect-disconnect PC • Check that the engine brake works correctly.
7 Check height regulation for air suspension Note: In D13 engines, the engine must be warmed up before the VEB (Volvo Engine Brake) is started.
• Check that the retarder is working correctly. Apply the retarder with care. If the oil has been
changed in the compact retarder, drive at a speed of approximately 50 km/h. Apply the retarder five
times in position 2 for approximately five seconds each time.
• Check for exhaust gas leaks when the vehicle is loaded.
• Check that the ABS control lamp switches off. If the lamp does not switch off, or if it switches off and
lights up. again, there is a fault in the system.
• Check that the blocked air filter warning lamp or symbol do not light up when driving.
gauge, AdBlue gauge, coolant temperature • Check that the clutch and the (manual or automatic) gearbox are working correctly.
2. Exterior light indicators • Check that the differential lock and the front wheel drive activation, plus the corresponding control
3. Direction indicators lamps, are working.
4. Speedometer • Check that the on-board computer display on the instrument panel is not showing any fault code for
the l-shift gearbox. If there is a fault, correct it and delete the fault code!
6. Control and warning lamps • Check the operating temperature of the engine (minimum 75°C).
7. Driver information display • Check that the heating system and the climate unit are working.
8. Engine related indicators • When driving, check that the windscreen wiper works and that it cleans the correct area.
9. Tachometer • When driving, check that the windscreen washer works and that the water jets reach the glass as
expected.
active trip meter.
5.Road Test/Check after road test Basic Annual
Road Test • Check that the parking brake works by carefully trying to move the vehicle with the
1 Check Warning and Control Lamps parking brake applied.
2 Check seat belt • Check that the power take-off engagement inhibitor is working. If the engine is
3 Check after start switched off with the power take-off engaged, it will disengage. The next time the
4 Check during road test engine is started, the power take-off will be disengaged, even if the switch is on.
5 Check after road test • Listen out for any abnormal noise coming from the engine compartment.
6 Connect-disconnect PC • Check that there are no leaks in the exhaust pipe and silencer joins.
7 Check height regulation for air suspension • If the vehicle is equipped with an automatic gearbox, the oil level must be checked
whilst the gearbox is hot after the driving test.
• Apply the parking brake.
• Place the gear selector in neutral with the engine running at approximately 1000
rpm.
• Clean the dipstick with clean paper (use cleaning paper from which pieces do not
temperature, trip meter, odometer, fuel break off).
gauge, AdBlue gauge, coolant temperature • Check the oil level using the dipstick.
3. Direction indicators • If necessary, add oil to, or drain oil from, the gearbox. Ensure that the oil is clean. The
4. Speedometer presence of dirt in the oil could damage the gearbox.
• Check the display to ensure that no fault code is stored in the vehicle control units. If
6. Control and warning lamps a fault is registered, correct it and delete it. Consult the appropriate service
7. Driver information display information as a guide to repairing any fault code.
9. Tachometer • Check that there no oil leaks or leaks of any other fluid.
active trip meter.
7.Road Test/Connect - disconnect PC Basic Annual
Road Test Connect-disconnect PC

1 Check Warning and Control Lamps The illustrations are re-used between different variants, certain details may
2 Check seat belt therefore deviate from the version described here. The essential information
3 Check after start
in the illustrations does, however, always correspond.
6 Connect-disconnect PC Connect the PC tool to the wagon's data link
7 Check height regulation for air suspension connector, which is located on the driver's side in
the lower edge of the instrument panel.

4. Speedometer Check the following points using the diagnostic tool:
auxiliary brake information Checking, rectification and resetting of fault codes
Brake linings checking
8. Engine related indicators Check of clutch wear (only applies to automatic gearbox)
9. Tachometer
10. Bogie and differential indicators If the air drier has been replaced during service, it must be reset
11. Control for trip meter* *A brief press on If the particulate filter has been replaced during service, it must be reset
meter T1 and T2. A long press resets the Disconnect the PC tool.
active trip meter.
7.Road Test/Check Height regulation for air suspen Basic Annual
Road Test
1 Check Warning and Control Lamps
2 Check seat belt
3 Check after start
Not Applicable
4. Speedometer
9. Tachometer
active trip meter.
8.External Check/Check Lighting and reflectors Basic Annual
External Check Head lamps

8 Check lighting and reflectors
9 Check engine oil level
Check fluid levels in windscreen and
10 headlamp Washer reservoirs
Check refrigerant tank, Condenser, pipes and
11 hoses
12 Check Coolant frost protection and fluid level
Check sealing on servo pump, oil
13 connections, oil hoses and steering gear
14 Check tire pressure
15 Check tire wear
Check fuel tank, hoses, air vent pipe and
Tail lights
16 mountings
17 Check air intake and air deflector
18 Check axial play, V -Stay
19 Check rear shock absorbers
Check batteries -dirt, leakage, attachment,
20 fluid level, connections and battery box
21 Check rear wheels
22 Check rear wheel bearings
23 Check silencer for Modulator
9.External Check/Check Engine Oil level Basic Annual
External Check
11 hoses
15 Check tire wear
16 mountings
10.External Check/Check fluid levels Basic Annual
External Check Washer fluid

Windscreen cleaning and headlamp cleaning have a
common tank, which holds about 15 liters of
9 Check engine oil level washer fluid. Use Volvo's washer fluid. When the
Check fluid levels in windscreen and level drops to the lowest alarm level, the headlamp
washing is switched off in favor of windscreen
washing. A filter is fitted under the filler cap. Do not
11 hoses
fill washer fluid without the filter.
15 Check tire wear
16 mountings
11.External Check/Check Refrigerant Tank Basic Annual
The illustrations are re-used between different variants, certain details may therefore
External Check
deviate from the version described here. The essential information in the illustrations
does, however, always correspond.
Check fluid levels in windscreen and • Check the attachments for the condenser
10 headlamp Washer reservoirs and refrigerant tank.
• Check that the condenser cooling ribs are
11 hoses
not damaged or blocked by insects and dirt
12 Check Coolant frost protection and fluid level that can obstruct the air flow. Use a mild
Check sealing on servo pump, oil degreasing agent and water when cleaning.
• Check that hoses, pipes and wiring are not
14 Check tire pressure damaged and that pipe and hose clamps are
15 Check tire wear intact.
16 mountings
19 Check rear shock absorbers • Check that the radiator and intercooler
attachments, side plates and rubber
pads are secure and in good condition.
• Visually check that bolt unions are
tight.
12.External Check/Check Coolant Basic Annual
External Check The illustrations are re-used between different

variants, certain details may therefore deviate from
the version described here. The essential information
9 Check engine oil level in the illustrations does, however, always correspond.
Check fluid levels in windscreen and Note: If coolant is being changed, depending on the
10 headlamp Washer reservoirs coolant's change interval, see Additional actions. Filler cap
11 hoses 1. Check the coolant's antifreeze protection (=
12 Check Coolant frost protection and fluid level protection against corrosion) with a hydrometer,
Check sealing on servo pump, oil 88890105. The antifreeze protection must be
13 connections, oil hoses and steering gear between -25 °C and -45 °C.
14 Check tire pressure 2. Top up with water and 50% concentrated coolant as
necessary. The coolant level should lie between the
15 Check tire wear
MIN and MAX markings on the expansion tank when
16 mountings the engine is cold. Fill with the same mixture that is
already in the cooling system. For information about
water and coolant quality, please refer to the service
18 Check axial play, V -Stay information group 26.
19 Check rear shock absorbers Always use coolant that meets Volvo Coolant Specification (VCS) standard 418-0001. If you are using
Check batteries -dirt, leakage, attachment, the Volvo branded coolant, you can recognize it by its yellow color and it is specially adapted for Volvo
engines. The coolant provides optimum antifreeze protection, while also preventing scale deposits and
21 Check rear wheels corrosion in the cooling and heating system.
23 Check silencer for Modulator Check that the filling and pressure caps are securely tightened by hand.
13.External Check/Check Sealing Basic Annual
External Check Engine must be running (approx. 1000 rpm).

• Check the servo system's pressure side for oil leakage
on the servo pump (two for double servo systems, one
9 Check engine oil level power steering pump on the engine and one on the
Check fluid levels in windscreen and gearbox), oil reservoir, hoses and tubes, steering gear
10 headlamp Washer reservoirs and hydraulic cylinder.
Check refrigerant tank, Condenser, pipes and • Stop the engine.
11 hoses
• Check for any air leakage on the suction side. Check for
12 Check Coolant frost protection and fluid level air bubbles in the power steering oil.
Check sealing on servo pump, oil • Make sure that hoses and tubes for the power steering
13 connections, oil hoses and steering gear are intact and do not scrape against anything.
14 Check tire pressure • Make sure that clamps for tubes and hoses have not
15 Check tire wear come loose.
16 mountings • Check the system for hydraulically steered pusher
17 Check air intake and air deflector axle or trailing wheel axle:
18 Check axial play, V -Stay • Make sure there is no oil leakage at the master
cylinder, hoses, tubes, fittings, nipples, flow
indicators and solenoid valves for the steering
system.
14.External Check/Check Tire pressure Basic Annual
External Check
11 hoses
15 Check tire wear
16 mountings
15.External Check/Check Tire Wear Basic Annual
External Check
11 hoses
15 Check tire wear
16 mountings
16.External Check/Check Fuel tank Basic Annual
External Check The illustrations are re-used between different variants, certain details may therefore
8 Check lighting and reflectors deviate from the version described here. The essential information in the illustrations
9 Check engine oil level does, however, always correspond.
11 hoses
15 Check tire wear
16 mountings
20 fluid level, connections and battery box • Check the fuel tank, hoses, pipes and mounting bands.
21 Check rear wheels • Check that there are no cracks or leaks.
22 Check rear wheel bearings • Check that the fuel tank's venting hose not is clogged.
23 Check silencer for Modulator • Check that pipes and hoses from the combined tank unit are clamped and are not
leaking or chafing.
• Check that the tank's mounting bands and mounting brackets are not loose or
cracked.
17.External Check/Check Air intake Basic Annual
External Check Check air intake and air deflector

8 Check lighting and reflectors The illustrations are re-used between different variants, certain details may therefore deviate
9 Check engine oil level from the version described here. The essential information in the illustrations does, however,
Check fluid levels in windscreen and always correspond.
• Check visually that the induction pipe is in good condition and that the rubber bellows seal
against the pipe to the air cleaner housing.
11 hoses
15 Check tire wear
16 mountings
• Check the attachment of brackets, rubber pads and screw unions for the air intake and
wind deflector.
• Check that there are no cracks on the wind deflector or its attachments.
18.External Check/Check Axial play, V-Stay Basic Annual
External Check
11 hoses
15 Check tire wear
16 mountings
Check the bolts and tightness
Check the Axial Play:

Move up and Down/Side to side
19.External Check/Check Rear Shock absorbers Basic Annual
External Check
11 hoses
15 Check tire wear
16 mountings
20.External Check/Check Batteries Basic Annual
External Check
11 hoses
15 Check tire wear
16 mountings
21.External Check/Check Rear Wheels Basic Annual
The illustrations are re-used between different variants, certain details may therefore
External Check
deviate from the version described here. The essential information in the illustrations
does, however, always correspond.
10 headlamp Washer reservoirs Disc wheel
11 hoses • Check the wheels for cracks and rust
12 Check Coolant frost protection and fluid level that can indicate loose nuts or broken
Check sealing on servo pump, oil wheel bolts.
15 Check tire wear
16 mountings
Spoke wheel
• Check that all the wheel nuts and retainers are in
20 fluid level, connections and battery box place. Note: It must be clean between wheel rim and
21 Check rear wheels hub, there must not be any rust.
22 Check rear wheel bearings • Check that the installation has been carried out
23 Check silencer for Modulator correctly, lift the axle and rotate the wheel. Check
that the wheel is centered.
22.External Check/Check Rear Wheel bearings Basic Annual
When the check is carried out, the rear of the vehicle must
External Check be raised and supported and the parking brake must be
8 Check lighting and reflectors released.
9 Check engine oil level • Check the clearance in the rear wheel bearings, using a
Check fluid levels in windscreen and rod in the hole in the wheel as a lever with which to
10 headlamp Washer reservoirs lift it. The bearings must normally be preloaded. For
Check refrigerant tank, Condenser, pipes and this reason, there must not be any clearance in the
11 hoses wheel bearings.
12 Check Coolant frost protection and fluid level • However, in certain cases there could be a clearance of
Check sealing on servo pump, oil up to 0.1 mm in the bearing.
13 connections, oil hoses and steering gear • If there is clearance in the bearings, this clearance
14 Check tire pressure must be measured using a dial indicator.
Note: Note down the clearance in the bearing!
15 Check tire wear
16 mountings 1. If the clearance in the bearing is less than 0.1 mm: turn
the wheel with a wheel-turning device. The drive
shaft must be removed from the drive wheel hubs. Listen
18 Check axial play, V -Stay for any abnormal noise in the bearings when they are being
19 Check rear shock absorbers turned.
Check batteries -dirt, leakage, attachment, The front and rear auxiliary wheel bearings must always be
20 fluid level, connections and battery box checked using a wheel-turning device.
22 Check rear wheel bearings 2. If the clearance in the bearing is 0.2 mm or more, the
hub bearings must immediately be replaced to avoid future
damage.
Note: Make a note of any abnormal noise in the rear wheel bearings.
Abnormal noise in the bearings is a sign that the bearing has suffered wear. The
hub bearings must be replaced.
23.External Check/Check Silencer for Modulator Basic Annual
External Check
11 hoses
15 Check tire wear
16 mountings
24.Engine Bay/Check drive belts and tensioners Basic Annual
Engine bay • Check that the belt tensioner

24 Check drive belts and belt tensioners works.
25 Check A/C Compressor for A/C Unit • Use a lever to alleviate the tension
Check for electrical connections and cable for
26 alternator, starter Motor and preheating unit in the belt tensioner and inspect
27 Check engine mountings
the roller bearings in the tensioner
28 Check radiator, hoses and pipes
and all of the support rollers.
29 Check hoses and pipes for the intercooler
Check radiator fan, fan shroud and fan ring
30 with rubber seal
Check engine, engine powered power take
31 off and compressor for leakeage
32 Check fuel piping and lines
33 Check for exhaust leakeage
34 Check air pipe between air intake and turbo
35 Check engine sound baffles
36 Check steering system, oil level check
• Check that none of the grooves in the belt is missing.

• Check that the belts are not cracked. Cracked belts must be replaced.
• There must not be any dirt or grease on the belts or the contact surfaces
of the belt pulley.
25.Engine Bay/Check A/C Compressor Basic Annual
Engine bay
24 Check drive belts and belt tensioners
25 Check A/C Compressor for A/C Unit
26 alternator, starter Motor and preheating unit
30 with rubber seal
Check A/C Compressor
26.Engine Bay/Check for Electrical Connections Basic Annual
Engine bay
30 with rubber seal
27.Engine Bay/Check Engine Mountings Basic Annual
Engine bay
30 with rubber seal
28.Engine Bay/Check Radiator, hoses Basic Annual
Engine bay The illustrations are re-used between different variants, certain details may therefore
24 Check drive belts and belt tensioners deviate from the version described here. The essential information in the illustrations
25 Check A/C Compressor for A/C Unit does, however, always correspond.
30 with rubber seal
• If there is a complaint about high coolant temperature, please refer to the service
information group 26.
• Check that the radiator is not damaged, does not leak and is securely fastened.
• Check that the coolant hoses or pipes are not chafed.
• Check ageing (hardness), cracks and delaminating (blisters) on the coolant hoses.
• Check that the hoses or pipes do not leak.
• Check externally that the radiator's pipe system is not clogged by insects or other
particles that may impede the through-flow of air. In the cases where the wagon is
equipped with insect screen, check that it is not clogged or damaged.
29.Engine Bay/Check hoses & pipes Basic Annual
Engine bay The illustrations are re-used between different variants, certain details may therefore
24 Check drive belts and belt tensioners deviate from the version described here. The essential information in the illustrations
25 Check A/C Compressor for A/C Unit does, however, always correspond.
30 with rubber seal
• Check that the charge air cooler is intact.

• Check that the hoses and pipes between the engine and the charge air cooler are
intact and do not chafe.
• Check clamps and bolted joints for the hoses and pipes between the engine and the
charge air cooler.
• Check externally that the charge air cooler's pipe system is not clogged by insects or
other particles that may
• impede the through-flow of air.
30.Engine Bay/Check Radiator fan Basic Annual
Engine bay
30 with rubber seal
31.Engine Bay/Check Engine, Engine powered Basic Annual
Engine bay
30 with rubber seal
Check tightness of engine, engine powered
31 power take off and compressor for leakage
• Check that there are no oil or coolant leaks in the engine.

• Check that the pipe joins, hose joins and flanges are not leaking.
• Check that the pipes and hoses are not cracked or rubbing against any other part.
• Check that the engine-driven power take-off and the pipes are not leaking.
• Check that the compressor is not leaking oil or coolant.
32.Engine Bay/Check fuel piping and lines Basic Annual
Engine bay
30 with rubber seal
31 off and compressor for leakage
36 Check steering system, oil level check • Check that the pipe and hose connections on the fuel lines are not leaking.
• Check that the fuel pipes are not leaking or rubbing against any other part.
33.Engine Bay/Check for exhaust leakage Basic Annual
Engine bay Exhaust gas leaks are detected by the

24 Check drive belts and belt tensioners presence of soot.
25 Check A/C Compressor for A/C Unit • Check the exhaust outlets in the
Check for electrical connections and cable for cylinder heads, the junctions and the
26 alternator, starter Motor and preheating unit flanges on the exhaust manifold for
27 Check engine mountings exhaust gas leaks.
28 Check radiator, hoses and pipes • Check for exhaust gas leaks in the
29 Check hoses and pipes for the intercooler exhaust gas pressure regulator, the
30 with rubber seal
exhaust brake and the joint clamps on
Check engine, engine powered power take the front exhaust pipe.
33 Check for exhaust leakage Check Clamps for loose Connections and Leakage

Check pipe for damages
Check Clamps for loose Connections

and Leakage
34.Engine Bay/Check air pipe between Basic Annual
Engine bay
26 alternator, starter Motor and preheating unit Check pipe for damages
30 with rubber seal
33 Check for exhaust leakage
Check pipe for damages

35.Engine Bay/Check Engine Sound baffles Basic Annual
Engine bay
30 with rubber seal
• The sound insulation located under the cab must be inspected to check
that it is in good working condition. This also applies to its attachment.
• If you notice that the component has suffered any deformation or
deterioration, or if the attachments have loosened or come free, the
component and/or its attachments must be changed. If this is not done
and the vehicle is used in this condition, the vehicle and/or third parties
could be damaged.
36.Engine Bay/Check Steering System Basic Annual
Engine bay
30 with rubber seal
37.Lubrication oil and fluid level check / Cab Lub Basic Annual
Lubrication oil and fluid level check

37 Cab Lubrication
38 Coupling Lubrication
39 Fifth wheel lubrication
40 Check oil level in gear box
Check sealing on the gearbox and power
41 take-off and check cables
Checking propeller shaft and universal joints,
42 slide joints and support bearings
Check sealing of real axle and hub reduction
43 gear
44 Check rear Axle ventilation
45 Check oil level in rear axle
Lubrication Point Lubricant

1. Lock and Hinge Grease, oil
2. Top foot step oil
3. Lower foot step oil
4. Key hole Lock oil
5. Striker plate, lock lug Paraffin
6. Locks, boot lids Paraffin
7. Cab lock Grease
Grease quality
Use lithium based lubricating grease with EP additive and consistency NLGI No. 2.
38.Lubrication oil and fluid level check / Coupling Lu Basic Annual

37 Cab Lubrication
43 gear
39.Lubrication oil and fluid level check / Fifth wheel Basic Annual

37 Cab Lubrication
43 gear
40.Lubrication oil and fluid level check / Check Oil Basic Annual
Lubrication oil and fluid level check Oil level

When the oil level in the gearbox is too low it must be
37 Cab Lubrication
refilled. The following oil grades must be used per service
38 Coupling Lubrication category:
39 Fifth wheel lubrication 1 Remove the sound baffle, if fitted, from underneath the
40 Check oil level in gear box gearbox
Check sealing on the gearbox and power 2 Check that the oil level is between the center and the
41 take-off and check cables maximum level on the level sight glass (A) in the gearbox
Checking propeller shaft and universal joints, (max and min oil level, see the figure).
42 slide joints and support bearings 3 Top up with oil as necessary, but first clean round the filler
Check sealing of real axle and hub reduction plug (B).
43 gear 4 Remove the air vent hose from the filler plug (B), and
44 Check rear Axle ventilation unscrew the plug.
45 Check oil level in rear axle 5 Fill with new oil until the oil level is between the center
and the maximum level on the level sight glass (A) (max and
min oil level, see the figure).
6 Apply thread sealant to the filler plug's (B) threads, and
screw in the plug. The tube on the plug must have the same
position diagonally upward as before removal.
7 Fit the air vent hose.
8 Refit the sound baffle, if fitted, under the gearbox.
Service intervals
The intervals for the gearbox oil vary greatly depending on
how the truck is equipped, what it is used for, the nature of
the terrain where it is driven, oil quality level, vehicle
combination gross weight, etc. Contact a Volvo workshop
in order to obtain a service schedule for your particular
truck.
41.Lubrication oil and fluid level check / Take-off Basic Annual

37 Cab Lubrication
43 gear
• Check that the gearbox, whether it be manual or automatic, is not leaking oil or coolant.
• Check that the power take-off is not leaking oil.
• Install the sound insulation, if equipped.
• If there is a leak, check the oil level.
42.Lubrication oil and fluid level check / Checking pr Basic Annual

37 Cab Lubrication
43 gear
1. With the gearbox in the neutral position, check the propeller shaft for runout or any other type of
damage.
2. Manually apply torsion to check if the universal joints have suffered any wear. There must not be any
clearance in the joints.
3. Visually check that the attachment bolts in the support bearings and flanges are tightened. Also check
that the lock rings are in the correct position.
4. If the propeller shaft is lubricated, lubricate all of the points in accordance with the lubrication chart.
5. Turn and raise the sliding joints to check for signs of wear.
6. Any wear suffered by the sides and tops of the grooves could give rise to movement in the sliding joint
which could lead to vibration and unbalancing. No value has been defined for this clearance. However,
it must be observed and noted down so that the situation can be explained to the customer.
7. Check the attachment of the support bearing bracket and the condition of the rubber pads. There
must not be any clearance between the rubber and the bracket.
43.Lubrication oil and fluid level check / Check seali Basic Annual

37 Cab Lubrication
43 gear
44.Lubrication oil and fluid level check / Check Rear Basic Annual

37 Cab Lubrication
43 gear
45.Lubrication oil and fluid level check / Check oil le Basic Annual
Lubrication oil and fluid level check GL 5 Grade OIL

37 Cab Lubrication Need to be used
39 Fifth wheel lubrication Oil Fill & Level Checking Plug
Intermediate axle
42 slide joints and support bearings Oil Drain Plug
43 gear
Rear axle
Oil Fill & Level Plug
Oil Drain Plug

46.Front Suspension, Steering Gear / Check Steering Basic Annual
Front Suspension, Steering gear

46 Check steering link system
• It is important to observe all of the instructions contained in this item in
47 Check king pin bearings order to avoid any possible accidents caused by inadequate
48 Check front shock obsorbers maintenance.
• Never weld steering system components.
49 Check front wheels
50 Check front wheel bearings Note: The components must be cleaned. Do not use solvents to carry out
this cleaning. Use only a cotton wipe or a clean cloth. Be careful when
cleaning to not damage the protective rubber on the ball joints.
• The best way to check the condition and any play on the mechanical
connections is to keep the vehicle
stationary with two mechanics working together.
• The cab must be in drive position. Align the wheels.
Mechanic 1 turns the wheel back and forth while mechanic 2 keeps the
lower portion of the steering column still.
• This check must be performed on both locks on the steering wheel's
adjustment range.
• Check that the steering wheel adjustment works.
Note: There must not be any play in the system. No abnormal noise/feel
may occur when the steering wheel is raised or lowered within its range of
adjustment. If any abnormal sounds/conditions are observed,
• Turn the wheel from one side to the other and check the play and
condition of mount and components. Check the link stay mount that is
connected to the axle (with or without activation of hydraulic system).
• When you turn the wheel to full lock, there must not be any relative
movement between the link stay or track rod and adjusting nut and ball
joint. Check for play between the components by putting a finger
between the link stay and the adjusting nut and another finger between
the adjusting nut and ball joint while the steering wheel is turned to full
lock both right and left.
Note: If there is any play between any of the components, the entire rod
(link stay or track rod, adjusting nut and ball joint) must be changed.
46.Front Suspension, Steering Gear / Check Steering Basic Annual
• Check for rust in the ball joint and adjusting nut threads. No components may show signs of rust, dents or damage. If
there is rust, the entire rod (link stay or track rod, adjusting nut and ball joint) must be changed.
Clamp position
47 Check king pin bearings
48 Check front shock obsorbers
50 Check front wheel bearings
• Check to make sure there is no play in the intermediate

steering shaft and hydraulic cylinder brackets on dual front
axles.
• Check the brackets on the steering arm, link stay and track
rod, and make sure the clamps are not damaged and are
properly tensioned.
• Note: Neither the screws in the clamp or the clamp itself may
be deformed in any way. If there is any deformation, the
components must be replaced with new Volvo original parts.
• The clamp nuts must be tightened to 80 ± 10 Nm for M12
screws and to 170 ± 10 Nm for M14 screws.
• At least three threads on the screws must be visible outside • Make sure that the rubber boots on the
the nut and the clamp must be positioned as shown in the ball joints on the link stay, track rod,
diagram. steering arm, extra hydraulic cylinder,
• Make sure that the pitman arm connected to the steering master cylinders, centering cylinders for Check
gear is properly secured and that the nut is tightened and the hydraulic pusher axle or rear trailing
correctly locked. wheel axle are in good condition and
• Check the mounting between the steering gear and the properly sealed.
bracket and the chassis frame to ensure there are no cracks • If a rubber boot is cracked or damaged,
or loose screw connections. the ball joint must be changed.
• Check the mounting on the intermediate steering shaft and Note: A cracked or damaged rubber boot
the hydraulic cylinders to ensure there are no cracks, no play significantly reduces the life of the ball joint.
and no loose screw connections.
47.Front Suspension, Steering Gear / Check King pin Basic Annual

47 Check king pin bearings
3. Use a tape measure and measure

from a fixed point, e.g. the frame.
Mark the distance at a space between
two wheel bolts. Raise/lever up the
wheel using e.g. a crowbar and
measure the change in position. See
the table below for measures
depending on the amount of play.
Vehicle with driven front axle

The steering knuckle attachments for
driven front axle have tapered roller
bearings, which are pre-tensioned
and should not have any play.
48.Front Suspension, Steering Gear / Check front sh Basic Annual

47 Check king oin bearings
48 Check front shock absorbers
49.Front Suspension, Steering Gear / Check Front W Basic Annual
Front Suspension, Steering gear Check front wheels

The illustrations are re-used between different variants, certain details may therefore deviate
47 Check king oin bearings from the version
48 Check front shock obsorbers described here. The essential information in the illustrations does, however, always
49 Check front wheels correspond.
Disc wheel
• Check the wheels for cracks and rust that can

indicate loose nuts or broken wheel bolts.
• Check that all wheel nuts and retainers are in
fitted in place.
• Check that the installation has been carried out
correctly, lift the axle and rotate the wheel.
Check that the wheel is centered.
Note: It must be clean between wheel rim and hub, there must not be any rust.
50.Front Suspension, Steering Gear/Check Front Wb Basic Annual

47 Check king oin bearings
51.Check underneath the vehicle/Check Exhaust pip Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear
Check exhaust pipe and silencer or particulate filter
51 Check steering
exhaust pipe
link system
and silencer
The illustrations are re-used between different variants, certain details may therefore deviate
52 Check king
anti -roll
oin bearings
bar
from the version described here. The essential information in the illustrations does, however,
53 Check front
springs
shock
and obsorbers
U-bolts always correspond.
54 Check front
chassis
wheels
frame and cross members
55 Check front
compressed
wheel bearings
air lines and hoses
56 Check air suspension bellows
57 Check sealing on the vehicle speed sensor Note: Vehicles equipped with a particulate
58 Check break linings filter: If, depending on the service interval of
59 Check break calipers, Cylinders, brake discs the particulate filter, the filter is to be cleaned,
60 Check break cylinder, Levers and forks see Additional measures.
61 Check clutch wear
• Check the condition of the sheet metal in the exhaust pipe and silencer or
particulate filter, if the vehicle has one.
• Check the flexible hoses and clamps.
• Check the mountings of the exhaust pipe and silencer or particulate filter for
cracks, loose screws, clamps, brackets and protective plates.
52.Check underneath the vehicle/Check Anti-roll bar Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti-roll
oin bearings
bar
53 Check front
springs
shock
and obsorbers
U-bolts
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses
57 Check sealing on the vehicle speed sensor
58 Check break linings
59 Check break calipers, Cylinders, brake discs
60 Check break cylinder, Levers and forks
53.Check underneath the vehicle/Check Springs & Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti -roll
oin bearings
bar
53 Check front
springs
shock
and obsorbers
U-bolts
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses
54.Check underneath the vehicle/Check Chassis fra Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti -roll
oin bearings
bar
53 Check front
springs
shock
and obsorbers
U-bolts
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses
55.Check underneath the vehicle/Check Compresse Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear Check compressed air lines and hoses
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti -roll
oin bearings
bar The illustrations are re-used between different variants, certain details may
53 Check front
springs
shock
and obsorbers
U-bolts therefore deviate from the version described here. The essential information in the
54 Check front
chassis
wheels
frame and cross members illustrations does, however, always correspond.
55 Check front
compressed
wheel bearings
air lines and hoses The compressed air system must be charged.
• Check compressed air lines and hoses with regard to air leakage, chafing,
cracks and external damage.
• Check that hoses near wheels and axles do not chafe during spring travel
and steering.
56.Check underneath the vehicle/Check Air Suspensi Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti -roll
oin bearings
bar
53 Check front
springs
shock
and obsorbers
U-bolts
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses
57.Check underneath the vehicle/Check Sealing on Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear Check sealing on the vehicle speed sensor
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti -roll
oin bearings
bar The illustrations are re-used between different variants, certain details may therefore deviate
from the version described here. The essential information in the illustrations does, however,
53 Check front
springs
shock
and obsorbers
U-bolts
always correspond.
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses
56 Check air suspension bellows Check that the seal for the speed
57 Check sealing on the vehicle speed sensor sensor on the gearbox is intact.
58.Check underneath the vehicle/Check break lining Basic Annual
Drum brakes
Check
Front Suspension,
underneath Steering
the vehicle
gear
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti -roll
oin bearings
bar
53 Check front
springs
shock
and obsorbers
U-bolts
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses
Check the thickness of the brake linings via the inspection holes in the
support plates. The minimum permitted thickness for the brake linings is 5
mm.
Check that no grease is leaking from the hubs onto the brake linings.
Note: Note down the thickness of the brake linings in the record sheet!
59.Check underneath the vehicle/Check break calip Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti -roll
oin bearings
bar
53 Check front
springs
shock
and obsorbers
U-bolts
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses
60 Check break cylinder, Levers and forks Not required(We do not have disc brakes)
60.Check underneath the vehicle/Check Break Cyli Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear Check brake cylinders, levers and forks
51 Check steering
exhaust pipe
link system
and silencer
The illustrations are re-used between different variants, certain details
52 Check king
anti -roll
oin bearings
bar may therefore deviate from the version described here. The essential
53 Check front
springs
shock
and obsorbers
U-bolts information in the illustrations does, however, always correspond.
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses • The pneumatic system must be charged to at least 7.5 bar. An
alternative to starting the engine is to use the pressure amplifier
56 Check air suspension bellows 9810621 for filling the system.
If the compressed air system is filled from an

external source, it should always be filled Check that the brake cylinders Check that the
through the air drier filler nipple to avoid and brake anchorages are brake levers and
moisture entering into the compressed air firmly fastened and that there brake forks are
system. The wheels must be blocked so that are no cracks. undamaged.
the vehicle cannot start to move.
Release the parking brake and apply the
footbrake, with the help of a pedal support or
an assistant. Check that the brake cylinder
seals correctly.
61.Check underneath the vehicle/Check Clutch Wea Basic Annual
Check
Front Suspension,
underneath Steering
the vehicle
gear
51 Check steering
exhaust pipe
link system
and silencer
52 Check king
anti -roll
oin bearings
bar
53 Check front
springs
shock
and obsorbers
U-bolts
54 Check front
chassis
wheels
55 Check front
compressed
wheel bearings
air lines and hoses
Max life up to (X = 30 mm)

62.Additional Services/Check Engine oil & Change fi Basic Annual
Additional Services
62 Change - Engine oil & filter Replace
64 Change - Gear box oil & Filter Replace
66 Change - Oil Change Rear axle hub reduction

67 Change - Power take off, oil
68 Replace - Power take off oil Filter
69 Replace - Fuel filter
70 Replace - Fuel Water separator Filter
71 Replace - Fuel tank air vent filter, replace
72 Replace - Primary Air filter element, replace
73 Replace - Secondary air filter element
74 Replace - Engine Coolant
75 Replace - Ventilation filter
76 Replace - Air drier element
77 Change - Clutch oil
78 Change - Steering oil
79 Replace - Steering oil filter
80 Replace - A/C air filter
81 Check & Adjust - Valves and Unit Injectors
82 Check all Wheel nuts & tightness
83 Check Clutch wear
84 Check Battery Status
85 Check Brakes and tyres
86 Check Revolving light
87 Check reverse alarm
88 Check First Aid kit
89 Check Fire Exhtinguisher
90 Check Engine Low idling RPM
91 Check Engine High idling RPM
92 Check Radiator Up & Lower Temperature
63.Additional Services/Replace Engine oil filter Basic Annual
Additional Services
62 Change - Engine oil and Filter Change
63 Replace - Engine oil Filter
64 Change - Gear box oil & Filter Replace
65 Replace -Gear box oil Filter
64.Additional Services/Check Gear Box Oil Basic Annual
Additional Services
64 Change - Gear box oil
65.Additional Services/Replace Gear Box oil filter Basic Annual
Additional Services
66.Additional Services/Change Oil Rear axle hub re Basic Annual
Additional Services
66 Change - Oil Rear axle hub reduction
67.Additional Services/Change Power Take Off Oil Basic Annual
Additional Services
68.Additional Services/Replace power take off oil fil Basic Annual
Additional Services
66 Change - Oil Rear axle hub reduction
80 Replace - A/C Air filter
69.Additional Services/Replace fuel filter Basic Annual
Additional Services
70.Additional Services/Fuel Water Seperator filter Basic Annual
Additional Services
71.Additional Services/Replace Fuel tank air vent fil Basic Annual
Additional Services
62 Change - Engine oil and Filter Change Fuel tank ventilation filter
71 Replace - Fuel tank air vent filter
72.Additional Services/Replace Primary Air filter Ele Basic Annual
Additional Services
Primary Filter Element
71 Replace - Fuel tank air vent filter
72 Replace - Primary Air filter element
82 Check all Wheel nuts & tightness Secondary Filter Element
73.Additional Services/Replace Secondary air filter Basic Annual
Additional Services
Primary Filter Element
71 Replace - Fuel tank air vent filter,
72 Replace - Primary Air filter element,
Secondary Filter Element
74.Additional Services/Replace Engine Coolant Basic Annual
Additional Services
75.Additional Services/Replace Ventilation filter Basic Annual
Additional Services
76.Additional Services/Replace Air Drier Element Basic Annual
Additional Services
76 Replace - Air Drier element ADU
77.Additional Services/Change Clutch Oil Basic Annual
Additional Services
78.Additional Services/Change Steering Oil Basic Annual
Additional Services
62 Change - Engine oil and Filter Change Power steering : In order for the power steering to work properly, you
63 Replace - Engine oil Filter must check the level in the oil reservoir and refill if required.
82 Check all Wheel nuts & tightness 1. Clean around the cap and oil dipstick.
83 Check Clutch wear 2. Check the oil level. With the engine switched off, the level must be at the max marking on
84 Check Battery Status the oil dipstick.
85 Check Brakes and tyres 3. Top up with oil as required. Some vehicles with dual-circuit steering systems have double oil
86 Check Revolving light reservoirs for the power steering.
Service intervals:- Normally the power steering oil does not need changing,
89 Check Fire Exhtinguisher however, the filter must be replaced during a repair.
91 Check Engine High idling RPM Oil recommendations :- (Oil grade : ATF oil, type Dexron III)
79.Additional Services/Replace Steering Oil filter Basic Annual
Additional Services
80.Additional Services/Replace A/C air filters Basic Annual
Additional Services
81.Additional Services/Check & Adjust valve & injec Basic Annual
Additional Services
82.Additional Services/Check All wheel nuts & Tight Basic Annual
Additional Services
83.Additional Services/Check Clutch Wear Basic Annual
Additional Services
91 Check Engine High idling RPM Max life up to (X = 30 mm)
84.Additional Services/Check Battery Status Basic Annual
Additional Services
The easiest way to check the charging is to use a voltmeter, but a
hydrometer (acid gravity meter), together with a voltmeter, gives
64 Change - Gear box oil a more accurate result. The graph shows standby voltage and
65 Replace -Gear box oil Filter state of charge compared to the acid’s density. * State of Charge
66 Change - Oil Change Rear axle hub reduction (Charge status)
78 Change - Steering oil Electrolyte level The level must be 5 - 10 mm above the cell
79 Replace - Steering oil filter plates. Top up the battery water if required. When filling, fill to
80 Replace - A/C air filter max 10 mm above the cell plates.
85.Additional Services/Check Brakes and Tires Basic Annual
Additional Services
85 Check Brakes and tires
86.Additional Services/Check Revolving light Basic Annual
Additional Services
off
75 Replace - Ventilation filter on
87.Additional Services/Check Reverse Alarm Basic Annual
Additional Services
88.Additional Services/Check First Aid Kit Basic Annual
Additional Services
89.Additional Services/Check Fire Extinguisher Basic Annual
Additional Services
89 Check Fire Extinguisher
90.Additional Services/Check Engine Low Idle RPM Basic Annual
Additional Services
62 Change - Engine oil and Filter Change Low idle - 600 RPM
600 RPM
91.Additional Services/Check Engine High Idle RPM Basic Annual
Additional Services
62 Change - Engine oil and Filter Change High idle - 2100 RPM
65 Replace -Gear box oil Filter 2100 RPM
92.Additional Services/Check Radiator Up & Lower Basic Annual
Additional Services

Volvo Truck Service Schedule Maintenace 1

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Volvo Truck Service Schedule Maintenace 1

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Volvo Trucks and Prime movers - Periodic Maintenance Training

1.Road Test/Check Warning & Control Lamps Basic Annual

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

1. Information display: clock, outside

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

1. Information display: clock, outside

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Road Test Connect-disconnect PC

1. Information display: clock, outside

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

External Check Head lamps

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

External Check Washer fluid

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

External Check The illustrations are re-used between different

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

External Check Engine must be running (approx. 1000 rpm).

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

External Check Check air intake and air deflector

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Check the Axial Play:

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Engine bay • Check that the belt tensioner

• Check that none of the grooves in the belt is missing.

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

• Check that the charge air cooler is intact.

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

• Check that there are no oil or coolant leaks in the engine.

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Engine bay Exhaust gas leaks are detected by the

34 Check air pipe between air intake and turbo

Check pipe for damages

Check Clamps for loose Connections

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Check pipe for damages

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Lubrication oil and fluid level check

Lubrication Point Lubricant

Service Schedule Based on Engine Hours (Hrs.) 400/800/1200/1600 2000

Lubrication oil and fluid level check