PV776-20 003739

This booklet replaces
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.
The following levels of observations, cautions and warnings are used

in this Service Documentation:
Danger: Indicates an unsafe practice where serious personal injury or
death could occur.
Warning: Indicates an unsafe practice where personal injury or severe
damage to the product could occur.
Caution: Indicates an unsafe practice where damage to the product
could occur.
Note: Indicates a procedure, practice, or condition that must be followed
in order to have the vehicle or component function in the manner
intended.
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, without
the prior written permission of Volvo Trucks North America, Inc..
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
3. Electrical System and Instruments

Specifications .........................................
Fuse and Relay Locations ....................
Tightening Torques ..............................
Group 35 Light Control Module ....
74
74
74
75
77
5. Brakes ...............................................
Specifications .........................................
Drum Brake .........................................
Compressor ..........................................
Air Drier ..............................................
Brake Valves ........................................
80
80
80
82
86
89
6. Suspension and Steering .................

Specifications .........................................
Wheel Alignment ................................
Steering ................................................
97
97
97
98
7. Chassis, Springs, Damping, and

Wheels .................................................
Specifications .......................................
Suspension .........................................
Wheels ...............................................
101
101
101
106
8. Body, Cab, and Interior Trim .......

Specifications .......................................
Cab Designations ...............................
Seats ...................................................
Climate Control Unit .........................
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
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, 10.9

Level
Action after choice
Low
Joints with low friction (μ

≈ 0.1)
None
Average
General application (μ ≈

0.15)
None
High
Application
Joints with high friction (μ

≈ 0.2) E.g. weld nuts of height
1
1d. , untreated steel surfaces, mm
Test
d = thread diameter
Thread
Strength class 8.8, Nm (ft-lb)

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)
0. General
Thread

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)
Thread

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
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
Parameter Identification Description

(identification of parameter (value))
PPID Proprietary Parameter Identification

Description (Volvo-unique
identification of parameter (value))
SID
Subsystem Identification Description

(identification of component)
PSID Proprietary Subsystem Identification

Description (Volvo-unique
identification of component)
FMI
Failure Mode Identifier

(identification of fault type)
0. General
MIDs
MID 128
MID 130
MID 136
MID 140
MID 142
MID 144
MID 146
MID 216
MID 232
MID 249
Engine Electronic Control

Unit (EECU)
Transmission ECU
Anti-lock Brake (ABS)
control unit
Instrument cluster
Satellite Communications
Vehicle control unit
(VECU)
Climate control unit
Lighting control module
(LCM)
Airbag (SRS), control
unit
Bodybuilder module
(BBM)
MID 250
J19391
J19392
J19393
J19394
Steering wheel module

(SWM)
Main network SAE J1939
Section of SAE J1939
connected to the vehicle
control unit
connected to the
instrument cluster
connected to the
bodybuilder control unit
0. General
Common Fault Codes

MID 128
Fault code diagnostics, refer to MID 128
fault codes, IMPACT or ID DVD: Info type
Diagnostics group 2841
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
EGR position sensor 2
EGR cooler efficiency
PSID 201
PID 362
EGR reed valve diagnose
SAE J1939 Data link interuption
Road speed sensor calibration

Total Vehicle Distance
EGR valve 2
Engine oil temperature
PID 245
Engine ECU (EMS2)
Air temperature, intake
PID 228
Data set memory EEPROM
Ambient temperature
PID 175
Program memory
Battery voltage
PID 172
5 Volt DC supply
Crankcase pressure
PID 171
SAE J1939 Control link
Engine coolant level
PID 158
Idle validation switch
Engine coolant temperature
PID 153
5 volt DC supply
Atmospheric pressure
PID 111
EGR valve 1
Intake manifold temperature
PID 110
Fuel supply pump
Intake manifold pressure
PID 108
Preheater element 2
Engine oil pressure
PID 105
Preheater element 1
Engine oil level
PID 102
Fan control
Water in fuel indicator
PID 100
Engine speed, flywheel sensor
Fuel supply pressure
PID 98
Engine position, cam sensor
Accelerator pedal position
PID 97
Drain Valve, Water Separator
Cruise control status
PID 94
1/2/3/4/5/6 Unit injectors
SID 18
PID 91
EPG 1
Vehicle speed
PID 85
VCB compression brake status
Preheater status
PID 84
High coolant temperature
EGR position sensor 1
PID 45
PPID 119
Fan speed %
PID 27
Engine brake torque percent
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
ABS sensor, axle 1 L
SID 10
ABS valve, axle 2 R
SID 2
ABS sensor, axle 1 R
SID 11
ABS valve, axle 3 L
SID 3
SID 12
ABS valve, axle 3 R
SID 4
SID 13
ABS retarder control relay
SID 5
SID 14
ABS relay, diagonal 1
SID 6
SID 15
ABS relay, diagonal 2
SID 7
ABS valve, axle 1 L
SID 18
ABS, ASR valve, diff 1
SID 8
ABS valve, axle 1 R
SID 19
ABS, ASR valve, diff 2
SID 9
ABS valve, axle 2 L
MID 140
Fault
code
Component / function
Fault
code
PID 77
Forward rear axle temperature
SID 240
Program memory
PID 78
Rear rear axle temperature
SID 250
SAE J1587/J1708 data link
PID 96
Fuel level
SID 253
Calibration memory, EEPROM
PID 116
Application air pressure
PSID 7
Internal reference resistance
PID 117
Air brake pressure, front
PSID 200
Open-circuit, J1939 Data Link, EECU
PID 118
Air brake pressure, rear
PSID 201
Open-circuit, J1939 Data Link, VECU
PID 158
Battery voltage
PSID 204
Open-circuit, J1939 Data Link, ABS
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
unit
PSID 210
Open-circuit J1939 Data Link, Lighting

control module
PSID 232
SAE J1939-3 Data Link
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
ORBCOMM satellite module/interface
SID 240
Memory flash/RAM
PSID 8
J1708/1587 road speed
SID 250
J1708/1587 Data Link
PSID 161
J1708/1587 VIN missing
SID 253
Memory ROM
PSID 162
VIN mismatch
PSID 3
Sending message failure
MID 144
Fault
code
Component
Fault
code
Component
PID 84
Vehicle speed
SID 231
SAE J1939 Control Data Link
PID 91
Accelerator pedal, percentage position
SID 240
Program memory
PID 150
PTO output (Volvo engine only)
SID 243
Cruise control, set switch
PID 152
VECU, number of resets
SID 250
Information link SAE J1708
PID 191
Output shaft speed
SID 253
Calibration memory EEPROM
PPID 61
Retarder switches (Volvo engine only)
PSID 4
Engine brake stalk lever (Cummins
PPID 69
Buffered idle validation switch (Volvo
6level engine brake only)
engine only)
PSID 200
Engine timeout
PPID 70
Pedal switches, supply
PSID 202
Instrument timeout
PPID 71
Cruise control and engine brake, switch
PSID 204
ABS/EBS timeout
PSID 210
LCM timeout
PSID 214
BBM timeout (VOLVO engine only,
supply
PPID 72
Accelerator pedal and engine brake,

sensors supply
PPID 74
VECU power supply
SID 230
Idle validation switch 1
vehicles equipped with BBM)
0. General
MID 146
Fault
code
Fault
code
PID 170
Cab, temperature sensor
SID 14
Circulation fan, temperature sensor, cab
PID 171
Temperature sensor, outer temperature
SID 15
Fan connection, engine
SID 2
Temperature sensor, evaporator
SID 16
Stepper motor, phase 1
SID 5
Stepper Motor, Fresh Air and
SID 17
SID 18
SID 19
SID 22
Pressure sensor, refrigerant, high
Recirculation
SID 6
Stepper motor, air distribution
SID 9
Stepper motor, air mixture Electronic

Climate Control (ECC), heat control
pressure side
Manual Climate Control, (MCC, BAS)

SID 232
5 volt supply to the sensor
compressor
SID 250
SAE J1708 data link
SID 12
Solenoid valve, water control
PID 170
Cab, temperature sensor
SID 13
Temperature sensor, heat exchanger
SID 11
Magnetic clutch, air conditioning (A/C)
10
0. General
MID 216
Fault
code
Fault
code
SID 240
Program memory
PSID 34
Power supply 1
SID 250
SAE J1587/1708 Information link
PSID 35
Power supply 2
SID 253
PSID 36
Power supply 3
SID 254
Control unit
PSID 37
Power supply 4
PSID 1
High beam, left
PSID 38
Power supply 5
PSID 2
Low beam, left
PSID 39
Power supply 6
PSID 3
High beam, right
PSID 40
Power supply, ignition key in driving
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
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
Fault
Code
Component/Function
Fault
Code
Component/Function
SID 1
Detonation circuit, airbag module
SID 254
Defective unit or component
SID 240
Program memory
PSID 1
Wrong VIN response
SID 253
Calibration memory
PSID 2
No VIN response
Fault
Code
Component/Function
Fault
Code
Component/Function
PID 29
Extra throttle control, percentage
PSID 201
SAE J1939 open circuit, Data Link,
MID 249
position
SID 230
Idle switch
SID 231
SID 253
PSID 200
vehicle ECU
PSID 202
instrument cluster ECU

PSID 205

automatic transmission ECU
engine ECU
MID 250
Fault
Code
Component/Function
Fault
Code
Component/Function
SID 231
PSID 6
Volume (-)
SID 251
Power supply, control unit steering
PSID 9
Headlamp interrupt
PSID 10
Marker interrupt
PSID 17
Power supply, switch steering wheel
functions (SWM)
SID 254
Control unit steering wheel module

(SWM)
PSID 3
Arrow left
PSID 4
Arrow right
PSID 5
Volume (+)
buttons
PSID 18
Data link, switch steering wheel buttons
12
0. General
FMI Table
FMI
Display Text
SAE Standard Text
Value too high
Correct value, but above normal working range
Value too low
Correct value, but below normal working range
Faulty data
Intermittent or faulty data.
Electrical fault
Abnormally high voltage or short circuit to higher voltage
Electrical fault
Abnormally low voltage or short circuit to lower voltage
Electrical fault
Abnormally low current or open circuit
Electrical fault
Abnormally high current or short circuit to earth (ground)
Mechanical faults
Faulty response from mechanical system.
Mechanical or electrical
fault
Abnormal frequency
Communication fault
Abnormal updating rate
10
Mechanical or electrical
fault
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
9pin Diagnostic Connector

Cavity
Position
Circuit Description
0Z (B-)
402 (B+)
406C (CAN_H, yellow)
407C (CAN_L, green)
not used
400G (SAE A, 1708)
401G (SAE B, 1708)
not used
196DR (Ignition)
The diagnostic connector is a round

connector located in the drivers side kick
panel. The diagnostic connector connects to
both the J1939 and J1587/1708 data link and
gives the system a way to communicate with
an external PC or diagnostic tool.
With a PC or diagnostic tool connected, fault
codes can be read from all the control units.
This is important in fault tracing to carry
out basic checks of all the vital parts of the
vehicles electronics.
Most programming can also be done via the
diagnostic connector.
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.
Vehicle Identification Label
The full 17-digit VIN is shown on the

Vehicle Identification label located in the
door opening on the drivers side. The VIN
contains the following information:
Manufacturing location
Engine type
Check sum figure
Assembly factory
Type of cab
Brakes / axle combination
Model year
Chassis number
Certification Label
W8003115
Three labels are located in the rear inside

frame of the driver side door frame. These
labels should not be removed.
On the top part of the door frame is the
Certification label showing the axle and load
ratings for the vehicle as it is built. DO NOT
exceed these ratings by overloading.
Noise Emission Control Label

The Noise Emission Control label is located
at the bottom of the three labels on the
rear inside frame of the driver side door. It
is the Owners responsibility to maintain
the vehicle so that it conforms to EPA
regulations.
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
The transmission label may include the type

of transmission, part number, serial number,
and service category. Location of the label
depends on transmission manufacturer.
16
1. Service and Maintenance
Oil Change Volumes
For the most current information on oil capacities

and oil change intervals, refer to Service Bulletin
175-60, Oil and Filter Change Intervals for VOLVO
Components.
For the most current list of approved oils for specific

applications, refer to Service Bulletin 175-61,
Approved Oils List, VOLVO Components.
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
Oil change volume, approx.
flywheel-mounted
5.0 L (5.3 qt)
17
Rear Axle
Model
Approx. oil change volume, L (qt)

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)
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
RS1352HV
22 L (23.2 qt)
3 L (3.2 qt)
28 L (29.6 qt)
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)
22.5 L (23.8 qt)
1.5 L (1.6 qt)
25.5 L (26.9 qt)
22.5 L (23.8 qt)
3 L (3.2 qt)
28 L (29.6 qt)
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)
RS1370HV
RT3210HV (front axle)
RT3210HV (front axle) Leaf springs

RT3210HV (rear axle)
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
Driving Front Axle

Model
FS0910HZ
11.5 L (12.1 qt)

Please note that the hub change volumes are not
included in these figures. The change volume for
each hub is 1.5 liter (1.6 qt).
Transfer Case
Model
VT2501TB
5.5 L (5.8 qt)
Hydraulic Retarder
Model
RET-TH

5.4 0.1 L (5.7 0.1 qt)
2. Engine
19
Specifications
General
Power Output 1
D12D 365
1800 Nm (1328 ft-lb)
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
272 kW (365 hp)
D12D 395
Torque 2
347 kW (465 hp)
2237 Nm (1650 ft-lb)
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
General Engine Specifications

Number of cylinders
Cylinder diameter
131 mm (5.16 in.)
Stroke
150 mm (5.91 in.)
Displacement
12.1 L (738.39 cubic

in)
Firing sequence
1-5-3-6-2-4
Compression ratio
17.3:1
Compression test using VCADS Pro, deviation from peak value

100%
max 20%
Engine speed during compression test, minimum
16.7 r/s (100 rpm)
Low idle
8.3 - 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
Engine
Cylinder
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
Front marking
arrow turned forward
Wrist pin diameter
55 mm (2.17 in.)
Piston Rings
Compression rings
Specification
Wear tolerance
Number
0.09 - 0.13 mm (0.0035 0.0051 in.)
Piston ring clearance in grooves:

lower compression ring
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
Width, including spring
4.32 mm
(0.170 in.)
Piston ring clearance in groove
0.05 - 0.10 mm
(0.0019 - 0.0039 in.)
Piston ring gap measured in ring

opening
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.)
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.)
Exhaust
43.1 mm (1.697 in.)
Oversize:
Intake
43.3 mm (1.705 in.)
Exhaust
43.3 mm (1.705 in.)
Height (B):
Intake
7.3 mm (0.287 in.)
Exhaust
8.0 mm (0.314 in.)
2. Engine
Valve Seat Location
Diameter (C) standard:
Intake
43.0 mm (1.693 in.)
Exhaust
43.0 mm (1.693 in.)
Diameter (C) oversize:

Intake
43.2 mm (1.701 in.)
Exhaust
43.2 mm (1.701 in.)
Depth (D) :
Intake
11.2 mm (0.441 in.)
Exhaust
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.)
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
< 0.2 mm (0.008

in.)
< 0.2 mm (0.008
in.)
Measurements are calculated for the method described in Service Information, group 21.
2. Engine
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.)
45 mm (1.77 in.)
Butt length max
40 mm (1.57 in.)
Exhaust
Outer valve spring (left-hand coil):
Length (unloaded)
73 - 74 mm (2.87 - 2.91 in.)
58 mm (2.28 in.)
1150 (850 ft-lb) Nm load
45 mm (1.77 in.)
Butt length max
40 mm (1.57 in.)
Inner valve spring (right-hand coil):

Length (unloaded)
70 - 71 mm (2.76 - 2.80 in.)
54 mm (2.13 in.)
41 mm (1.61 in.)
Butt length max
37 mm (1.46 in.)
Rocker Arms
Bearing play, maximum
< 0.1 mm (0.0039 in.)
Rocker arm roller, play, maximum
< 0.1 mm (0.0039 in.)
27
28
2. Engine
Timing Gears and Camshaft

Timing 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
C2001718
Number of teeth:
1
Drive gear, crankshaft
38
Intermediate gear, coolant pump
83
Drive gear, coolant pump
27
Drive gear, air compressor
29
Drive gear, camshaft
76
Intermediate gear (adjustable)
97
Drive gear, power steering pump
23
Drive gear, (pulley and fuel pump)
27
Intermediate gear
71
10
Drive gear, hydraulic pump
39
11
Drive gear, lubrication oil pump
23
12
Intermediate gear, lubrication oil pump
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
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 (0.0019
in.)
Bearing, permitted wear diametrical
0.05 mm (0.0019
in.)
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

Unit injector, stroke
< 0.1 mm (0.0039

in.)
17 mm (0.67 in.)
2. Engine
Camshaft bearing thickness, standard
31
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 clearance 1

Main bearing radial clearance
0.10 - 0.40 mm (0.0039 - 0.0158 in.)

1
0.046-0117mm (0.0018-0.0046 in.)
Out-of-round, main bearing and connecting rod

bearing pins, maximum
Taper on main bearing and connecting rod bearing
pins, maximum
0.05 mm (0.0020 in.)
Run-out of the center bearing, maximum

1
0.08 mm (0.0031 in.)
0.15 mm (0.0059 in.)
Measurements assume lubricated component.
32
2. Engine
Main Bearing Journals

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

(0.008 in.)
47.375 - 47.425 mm (1.8652 - 1.8671 in.)

(0.012 in.)
47.575 - 47.625 mm (1.8730 - 1.8750 in.)
Fillet radius (R)
3.75 - 4.00 mm (0.148 - 0.157 in.)
2. Engine
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.)
33
34
2. Engine
Connecting Rods
T2019085
FRONT on the shaft is turned

forward. Connecting rod and
cap are marked as a pair with a
three-figure serial number.
T2012874
Length center - center (E)
260 mm (10.236 in.)
Connecting rod bushing internal diameter (G)
55 mm (2.165 in.)
1
Axial clearance, connecting rod - crankshaft, maximum :

Connecting rod bearing, radial clearance, maximum 1:
0.10 mm (0.0039 in.)
Out-of-true, max deviation on measuring length of

100 mm (330 ft)
0.06 mm (0.0024 in.)
Torsion, max deviation on measuring length of 100 mm

(330 ft)
1
0.25 mm (0.0059 in.)
0.15 mm (0.0059 in.)
Measurements are with lubrication.
2. Engine
Connecting Rod Bearing Pins

(Only for check values, not machining)
Diameter () 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.)
35
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 Systems

Oil 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 - 95
(167 - 203 F)
1
C
65 - 105
C (149 - 221
F) 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)
Fine filter (is tightened 3/4 - 1 turn after contact)
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 System
Fuel 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 an
additional 3 - 4 flats (180 240).
Preload setting, 3 - 4 flats (see

illustration) ...............................................
0.75 0.1 mm (0.0295 0.0039 in.)
Cylinder Balancing
Cylinder balancing, VCADS
Compensation, maximum
80%
40
2. Engine
Intake and Exhaust System

Turbocharger
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
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
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
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
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
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
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
Charge Air Temperature Sensor

Cold engine (off)
Ambient temperature
Warm engine (running, vehicle standing still); coolant

temperature 75 - 95 C (167 - 203 F)
10 - 30 C (50 - 86 F) above
ambient 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%
Accelerator pedal
at rest (released)
Heat retention deactivated:

Coolant temperature
Engine load
> approx. 50%
Accelerator pedal
1
> 70
off idle (depressed)
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
EPG Activation for Idle EGR

Air pressure for exhaust pressure governor
(EPG)
approx. 100 kPa (14.5 psi)
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)
2way switch can give 100% (high) EPG only
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
> 900 rpm
vehicle speed
> 5 km/h (3 mph)
Deactivated:
engine speed
< 800 rpm
vehicle speed
< 5 km/h (3 mph)
VCB
Activated:
engine speed 1
> 1100 rpm
vehicle speed
> 5 km/h (3 mph)
engine oil temperature
> 55
C (131
F) 2
> 60
C (140
F) 3
charge air pressure
< 50 kPa (7 psi)
Deactivated:
engine speed1
vehicle speed
< 55
charge air pressure
< 5 km/h (3 mph)
< 1000 rpm
> 70 kPa (10 psi)
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
15 kPa (2.18 psi) (4.4 in. Hg)
Tuned muffler (D12D-465), maximum

1
20 kPa (2.9 psi) (6 in. Hg)
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
Speed, not engaged
500 - 1000 rpm
Engagement temperature
75
C (167
F) in front of fan
47
48
2. Engine
Electronically Controlled Viscous Fan

Activated system
Condition
Coolant temperature
Start temperature 90
(194 F)
Coolant temperature
> 93
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) example
engine speed 1500 rpm x
120% = 1800 approx. fan
speed
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 (28
mph)
1000 rpm
Ambient temp > 35 C

10km/h (6 mph)
1200 rpm
Ambient temp > 20 C

20km/h (12 mph)
600 rpm
AC system (a/c compressor

magnetic clutch activated)
Fan RPM Requested

C
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)
Engine ECU temperature
ECU temperature > 100

C (203 F)
Intake manifold air temperature

(VHD 465 hp only)
> 80 C(176 F) for more than 2.5s, deactivates below

70 C(158 F) for more than 5s
AC system
Refrigerant pressure > 20 bar (300 psi)
Thermostat
Quantity
Opening temperature
82
C (179
F)
C (196
F), deactivation 87
C (212
C (189
F), deactivates < 95
50
2. Engine
Engine Control System

Engine ECU
Note: The EECU may not be replaced without
prior authorization from Volvo; refer to Service
Information, Engine ECU, Fault tracing, IMPACT or
ID DVD: Info type Diagnostics group 2841.
Number of
pins
2 x 62
Sensors
Charge air sensor
Check value
1.05 1.30 V (normal atmospheric pressure)
Intake air temperature sensor
T2019008
2. Engine
Coolant temperature sensor
T2019009
51
52
2. Engine
Intake temperature sensor
T2019010
2. Engine
Engine oil temperature sensor
T2019011
Camshaft sensor
Distance to
camshaft
0.3 - 1.0 mm (0.012 0.039 in.)
Resistance
measurement
775 - 945
Flywheel sensor
Distance to
flywheel
0.7 - 2.1 mm (0.028 0.083 in.)
Resistance
measurement
775 - 945
53
54
2. Engine
Crankcase Pressure Sensor

Sensor alarm limit
> 8 kPa (1.2 psi)
Crankcase
pressure: normal
value (VEB not
active) regardless
of engine speed,
maximum
1.0 kPa (0.13 psi)
2. Engine
55
Tightening Torques and Patterns

Group 20
Tightening
M6 standard screw 8.8
10 1.5 7.4 1 Nm (89 13

inch-lb)
24 4 Nm (18 3 ft-lb)
48 8 Nm (35 6 ft-lb)
85 15 Nm (63 11 ft-lb)
140 25 Nm (103 18 ft-lb)
190 35 Nm (140 26 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 damage
under the head) must be replaced.
56
2. Engine
Group 21
Tightening:
Torque
Front engine mounting, cylinder block
175 20 Nm (129 15
ft-lb
Front engine mounting, crossmember
85 15 Nm (63 11
ft-lb)
Rear engine mounting, flywheel casing
Angle
245 35 Nm (181 27
ft-lb)
Rear engine mounting, rubber cushion

step 1
175 5 Nm (129 4
ft-lb)
step 2
255 38 Nm (188 28
ft-lb)
Main bearing cap

step 1
150 20 Nm (110 15
ft-lb)
step 2
120 5
Connecting rod cap

step 1
275 15 Nm (204 11
ft-lb)
2. Engine
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)
Piston cooling valve, screw

1
screws may not be reused.
24 4 Nm (18 3 ft-lb)
90 5
57
58
2. Engine
T2006973
Flywheel, tightening sequence (ensure that flange is dry and clean).
Tightening:
Torque
Angle
Flywheel (tighten screws in numerical order as illustrated):

step 1
step 2
60 5 Nm (44 4 ft-lb)
60 5
2. Engine
T2019062
Flywheel housing, tightening sequence.
Tightening:
Torque
Flywheel housing
140 14 Nm (105 10
ft-lb)
Note: Apply a string of silicone as illustrated,

thickness 2 mm (0.08 in.), max. 20 minutes
before assembly.
Angle
59
60
2. Engine
T2014027
Vibration damper, VN
tightening sequence.
Tightening:
W2004219
Vibration damper, VHD

tightening sequence.
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
Valve cover, tightening sequence
Note: If the valve cover is replaced, a new Engine

Certification Label must be printed and affixed to the new
valve cover. A new label can be printed from VCADS
Pro 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
Tightening:
Torque
Angle
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
Option 2
38 4 Nm (28 3 ft-lb)
60 5
after contact
Lock nut, valve yoke (EPG)
60 5
after contact
Lock nut, valve yoke (VEB)
60 +10/-0
after contact
2. Engine
T2012850
Bearing cap, camshaft/rocker arm shaft, tightening sequence
Tightening:
Torque
Angle
15 5 Nm (11 4 ft-lb)
90 5
Bearing cap, camshaft/rocker arm shaft

step 1
step 2
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
step 4 (loosen the screws)

step 5
1
Screws must be tightened in stages to ensure that the rocker arm shaft comes down without bending.
63
64
2. Engine
T2019046
Timing gear cover, lower
Tightening:
Torque
Timing gear cover, lower:

Step 1: Apply a thin bead 1 of silicone as illustrated, including around the marked hole
no more than 20 minutes before assembly.
Step 2: Working from center outward, tighten to
1
Solid line = 2 mm bead; dashed line (area A) = 1 mm bead.
34 4 Nm (24 3 ft-lb)
2. Engine
T2019925
Timing gear cover, upper

Note: When the upper timing gear cover is installed, the top section must
be flush with the cylinder head.
Tightening:
Torque
Timing gear cover, upper:

Step 1: Apply a thin bead of silicone 1 as illustrated, including around the marked holes,
no more than 20 minutes before assembly.
Step 2: Tighten screws in order as illustrated:
M8
M10
1
24 4 Nm (18 3 ft-lb)
48 8 Nm (36 6 ft-lb)
Thickness 2 mm.
65
66
2. Engine
W2004477
Gear train
Timing gears: use the following torques

(and angles, when indicated) for the
corresponding gear; follow the tightening

sequence for each gear as illustrated.
Tightening:
Torque
Angle
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 18
ft-lb)
F.
Idler gear
15 3 Nm (11 2 ft-lb)
120 5
2. Engine
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)
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
Pipe being reinstalled
60
2. Engine
T2014088
Oil cooler, cover; always use guide pins when installing the cover on the
engine.
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 the

middle outwards (14); see illustration
24 4 Nm (18 3 ft-lb)
Check tighten screws A and D
24 4 Nm (18 3 ft-lb)
69
70
2. Engine
Group 23
Tightening:
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 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
Exhaust manifold (refer to illustration for tightening

sequence):
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)
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
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)
71
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 engine

version number 1 in the image has been
removed. Front and rear bracket are the same

on 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 26
Thermostat, 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
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
TEC in Center Dash

Tightening Torques
Delco 42MT
1
2
3
4
5
Melco Gear Reduction
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 Specifications for Ring Terminals

Cab 12V Power Connections
Pass-through power stud
Torque Specification
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)
Startermounted 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)
77
Group 35 Light Control Module
W3005269
T3014623
The Light Control Module (LCM) controls all

exterior lighting functions. Interior lighting
in the cab and optional extras installed
on the vehicle are not part of this system.
In addition, it controls the intermittent
windshield wiper function and the wiper
function when the windshield washer is

used. The control unit communicates via the
J1587/1708 information link and the J1939
control data link as MID 216. See MID
216 page 10
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
Light Switch Troubleshooting

The LCM operates by interpreting a combination of ground and open signals from terminals
1 & 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.
Position
Terminal
1
Function
2
Open
Daytime running lights
Parking lights
(B)
Daytime running lights, Tail lights, Parking

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

lights, Side marker lights
Headlights with
auxillary lights
(D)
Open
High beam / low beam, Auxiliary lights

(driving/fog), Tail lights, Parking lights, Side
marker lights
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
Measure the brake lining thickness, If the

brakes are equipped with backing plates,
measure through the inspection holes in the
plate. Reline the brake shoes if the lining
thickness is 6 mm (.25 in) or less at the
middle of the shoe.
Note: Check the brake drums for and visible
cracks 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 .................................................
Cooling, cylinder head ..............................................
Fluid
Cooling, cylinder ......................................................
Air
Air capacity at back pressure of 800 kPa (8 bar) and

compressor speed of 2000 rpm .................................
440 dm/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 cm (21 in)
PR function:
Cylinder stroke PR-piston reed valve .......................
10-15 mm (.39-.59 in.)
5. Brakes
Tightening Torques
Tightening:
Torque - Nm (ft-lb)
Drive gear wheel .......................................
200 - 250 (147 - 184)
Union, outlet pipe .....................................
130 20 (95 14)
Unions for oil hoses, compressor and engine

block ..........................................................
25 4 (18 2.9)
Cylinder head bolts, 4pcs (1-4). Refer to

illustration below for correct tightening
sequence ....................................................
25 2 (18 1.4)
90
Bolted joints, valve plate 4pcs (5-8). Refer

to illustration below for correct tightening
sequence ....................................................
10 1 (7.3 .7)
90
Union, PR connection to compressor .......
25 4 (18 2.9)
Bolted joint, compressor mounting ...........
8515 (62 11)
T5012871
Angle
83
84
5. Brakes
2COM1080 VERSION2
T5012038
Make .........................................................................
WABCO 704
Volvo part no. D12 engine .......................................
20382347
Type ..........................................................................
Piston compressor
Number of cylinders .................................................
Cooling, cylinder head ..............................................
Fluid
Cooling, cylinder ......................................................
Air
Air capacity at back pressure of 800 kPa (8 bar) and

compressor speed of 2000 rpm .................................
800 dm/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 cm (43 in)
PR function:
Cylinder stroke PR-piston reed valve .......................
10-15 mm (.39 - .59 in)
5. Brakes
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 engine

block ..........................................................
25 4 (18 2.95)
Cylinder head bolts 6pcs (1-6).
25 2 (18 1.47)
90
Valve plate bolts 4pcs (7-8). Refer to

illustration below for correct tightening
sequence ....................................................
7 2 (5 1.47)
90
Nipple, PR connection to compressor .......
25 4 (18 2.95)
Bolted joint, compressor mounting ...........
85 15 (62 11)
Note: After the screws (1-6) are torqued

tight, check by turning screw (1) once again.
Refer to illustration below for correct
tightening sequence ...................................
T5012835
85
86
5. Brakes
Air Drier
Wabco SS1200P
Height
284 mm (11.2 in.)
Voltage .....................
12 V
Working Pressure .....
10.3 bar (150 psi)
Maximum flow
capacity ...................
1416 L/min (50 cfm)
Heater power ............
100 W
Wabco System Saver Twin

Height .......................
322 mm (12.6 in.)
Maximum width .......
320 mm (12.6 in.)
Voltage .....................
12 V
Working Pressure .....
10.3 bar (150 psi)
Maximum flow
capacity ...................
1416 L/min (50 cfm)
100 W
Bendix ADIP
Height .......................
360 mm (14.18 in.)
235 mm (9.27 in.)
Weight ......................
13 kg (28 lb)
Voltage .....................
12 V
Maximum flow
capacity ....................
850 L/min (30 cfm)
90 W
5. Brakes
Bendix AD-9
Height .......................
360 mm (14.25 in.)
235 mm (9.75 in.)
Weight ......................
13 kg (28 lb)
Voltage .....................
12 V or 24 V
Maximum flow
capacity ....................
481 L/min (17 cfm)
90 W
Midland Pure Air Plus

Height .......................
384 mm (15.1 in.)
236 mm (9.31 in.)
Weight ......................
8 kg (18 lb)
Voltage .....................
12 V
Maximum flow
capacity ....................
710 L/min (25 cfm)
95 W
87
88
5. Brakes
CR Turbo 2000
Height .......................
413 mm (16.25 in.)
216 mm (8.5 in.)
Weight ......................
7.5 kg (16.5 lb)
Voltage .....................
12 V
Maximum flow
capacity ....................
850 L/min (30 cfm)
75 W
5. Brakes
Brake Valves
Treadle Valve
Main brake actuation valve, foot operated.
Make, Model
Bendix, E6
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 Valve

Dash mounted valve for application and
release of park brake system.
Single button valve
Make
Meritor Wabco
150 PSI (10.3 bar)
Control of park brakes for vehicles not

intended 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
89
90
5. Brakes
(Park Brake Control Valve continued)

Dual button valve
Make
Meritor Wabco
150 PSI (10.3 bar)
Control of park brakes for vehicles intended

to 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 Valve

Dash mounted brake application valve
generally used to apply trailer brakes
Make
Meritor Wabco
150 PSI (10.3 bar)
Pressure delivery
Modulated pressure from 0 to system

pressure depending on handle position.
Connections, all Push-to-Connect (PTC)

built-in cartridges.
Supply port
Delivery port
Exhaust port
5. Brakes
Quick Release Valve
For rapid release of brake application air on
the front wheels.
Make
Meritor Wabco
150 PSI (10.3 bar)
Crack pressure
3 PSI (0.2 bar)
Connections
Supply port
1/2 NPTF
Delivery port
3/8 NPTF
Quick Release Valve with Double Check

For rapid release of park brake air on the rear
wheels. Use for tractors.
Make
Meritor Wabco
150 PSI (10.3 bar)
Connections
Supply port
1/4 NPTF
Anti-compounding port
1/4 NPTF
Delivery port
3/8 NPTF
91
92
5. Brakes
Inversion Relay Valve

For application and release of parking brake.
In the event of an emergency due to air
pressure loss in the primary air reservoir
(rear air brake circuit), this valve allows
modulated control of the rear brakes through
the spring brake chambers by use of the
secondary air control (front brake circuit).
Make
Meritor Wabco
150 PSI (10.3 bar)
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
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
150 PSI (10.3 bar)
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 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
Relay Valve and ABS Modulator Valves Assembly

Rear brake control valving, can also include
an additional solenoid valve in the assembly
for traction Control function.
Make
Meritor Wabco
150 PSI (10.3 bar)
Crack pressure
5.5 PSI (0.4 bar)
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
150 PSI (10.3 0.7 bar)
One Way Check Valves

Located in the primary and secondary air
reservoirs to protect against air loss, one in
each air tank.
Make
Norgren or Bendix depending on the air tank

installed.
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
150 psi (10.3 bar)
Opening pressure
8510 psi (5.90.7 bar)
Closing pressure
677 psi (4.60.5 bar)
Port
Connection
Supply port
1/2 PTC
1/4 PTC
3/8 PTC
95
96
5. Brakes
Pneumatic Electric Interface Panel
W5001392
AP-TD
Application air pressure, transducer
REAR SUP
Rear air suspension, transducer
SLS
Stop light switch
FRT SUP
Front air suspension, transducer
PBS
Parking brake, switch
B-TD
B tank, transducer
PARK
Pneumatic connection/air line connection
A-TD
A tank transducer
B-Tank
10
A-Tank
11
Cab power supply (+ )
6. Suspension and Steering
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 ........................................................................
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 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
Elasticity/slack in lower steering column, steering column

in 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 in

pedal anchorage ..........................................................
1
Zero slack
5 mm (0.19 in.)
When the steering column is pulled out, outside the ordinary driving position, slack is permissible
Power Steering Gear

Model
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)

Power Steering Pump
Engine
VOLVO D12
Cummins CU15 (ISX)
Rotation
Drive type
Displacement /rev (cm3)
cw
gear
18 (VN)
18-25 (VHD)
cw
spline
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)
99
100
Tightening Torques
Steering Wheel
Steering wheel center bolt
85 15 Nm (63 11 ft-lb)
Note: Steering wheel center bolt is not to

be reused
Steering Column
Upper steering column attachment
bolts
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
Specifications
Suspension
Location
Diameter
Grade
Torque
U-Bolts for Suspension

VN Front Mechanical
Suspension
M20
VN Front Air Suspension
M20
420 Nm (310 ft-lb)
VHD Front Suspension
M20
550 Nm (405 ft-lb)
VN, VHD Volvo T-Ride

Rear Suspension (38,000
M16
200 Nm (150 ft-lb)
M20
500 Nm (370 ft-lb)
M20
350 Nm (260 ft-lb)
M24
600 Nm (445 ft-lb)
VN, VHD Volvo Multi-leaf

Rear Suspension (4x2)
M22
500 Nm (370 ft-lb)
VN Volvo Rear Suspension

(VOAS)
M20
500 Nm (370 ft-lb)
M24
575 Nm (425 ft-lb)
Radius Spring to Spring Hanger

Bracket
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-Mounted

Bracket
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 to

Frame
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 Leveling

Valve to Frame
M14
10.9
200 45 Nm (148 33 ft-lb)
46,000 lbs.)
VN, VHD Volvo T-Ride

Rear Suspension (48,000
70,000 lbs.)
550 Nm (405 ft-lb)
102

Location
Diameter
Grade
Load Leveling Valve Control

Arm to Lever on Valve and Air
Bag Pedestal
M6
8.8
10 1.5 Nm (7 1 ft-lb)
Spring Hanger Bracket to

Frame
M14
10.9
200 45 Nm (148 33 ft-lb)
Torque
103
Ride Height and Pinion Angle Specifications

Frame 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
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
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
Dana 404
DST 40
Meritor MT4014M
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
104
Frame Height, mm (in.)
Ride Height mm (in.)
Pinion Angle
(Drive axle 1)
220 5 (8.7 0.2)
Pinion Angle
(Drive axle 2)
3.5 1
4X2 VOAS with any Axle

266 (10.47)
RR H200
Table 1. Ride Height and Corresponding Pinion Angle as measured from the axle center to
the frame rail bottom (unloaded).
As measured from the axle center to the frame rail bottom. *In the event that both the ride
height and pinion angles can not be adjusted at the same time for 6X4s, the ride height
should be adjusted to the minimum cancellation error angle for the intermediate prop shaft,
then lowered by 10 mm.
Note: Working angles are measured at the
forward axle joint or rear axle joint.
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)
Wheel Nuts, Tightening Torque
W7000774
Tightening sequence
All disc wheels for the VN and VHD-series

have nuts that require torque of 610 Nm
(450 ft-lb). For dual wheels, the following
procedure must be used.
1
Loosen nuts.
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 manufacturers
specifications.
107
108
8. Body, Cab, and Interior Trim
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)
L=long hood, M=medium hood
W8003128

Seats
Tightening Torques
Drivers 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 Isringhausen
seats ...........................................................
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)
109
110
Climate Control Unit

Specifications
General
Refrigerant, type .......................................
R134a (Tetraflourethane)
Air conditioning, volume .........................
1400 g - day cabs

1600 g - VN 430, 630
1700 g - VN 670, 780
Compressor, marking ...............................
SD 7H15
No. of cylinders ........................................
Cylinder volume .......................................
155 cm (9.5 in)
Compressor coupling ...............................
Electromagnetic
Lubricating oil capacity ...........................
300 cc (10.14 oz)
Pressure Monitor Switch Points

Note: Since the pressure transducer is
downstream of the compressor, gauge
readings could be .5 bar (7.3 psi) to 1.5 bar
(21.8 psi) higher if the gauge is used at the
compressor 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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This booklet replaces

The following levels of observations, cautions and warnings are used

Volvo Trucks North America, Inc.

Order number: PV776-20 003739

3. Electrical System and Instruments

6. Suspension and Steering .................

7. Chassis, Springs, Damping, and

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

0.6 0.1 (0.4)

3.5 0.5 (2.5)

1.5 0.5 (1.1)

15 2.5 (11 1.8)

30 4.5 (22 3.3)

Strength Classes 8.8, 10.9

Action after choice

Joints with low friction (&mu;

General application (&mu; &ap;

Joints with high friction (&mu;

Strength class 8.8, Nm (ft-lb)

15 2.5 (11 1.8)

100 15 (74 11)

115 20 (85 15)

140 25 (103 18)

160 25 (118 18)

185 30 (137 22)

220 35 (162 26)

255 40 (188 30)

250 40 (185 30)

290 45 (214 33)

340 50 (251 37)

Strength class 8.8, Nm (ft-lb)

360 55 (266 41)

430 70 (317 52)

500 80 (369 59)

490 80 (362 59)

580 90 (428 66)

680 100 (502 74)

620 100 (458 74)

740 120 (546 89)

860 140 (635 103)

Strength class 10.9, Nm (ft-lb)

7.5 1.2 (5.5 1)

105 20 (77 15)

125 20 (92 15)

150 25 (111 18)

175 30 (129 22)

200 30 (148 22)

230 35 (170 26)

275 45 (203 33)

320 50 (236 37)

310 50 (229 37)

360 55 (266 41)

410 60 (303 44)

450 70 (332 52)

540 90 (399 66)

630 100 (465 74)

610 100 (450 74)

730 120 (539 89)

850 140 (627 103)

750 120 (554 89)

900 140 (664 103)

1050 160 (775 118)

Parameter Identification Description

Joints with low friction (μ

General application (μ ≈

Joints with high friction (μ