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TRAINING TIPS &

TACTICS

Module 1- foundation

Contents
Brand image
Core values
Impact
Safe working practices
Service and Inspection

Introduction
About this
Pocket-guide

This guide is intended as a memory jogger for the


knowledge you have gained during your training course.
The guide includes a summary of the material covered in:
Module 1 - of the Volvo Truck Technical Training Plan.

Use IMPACT

This guide is not intended as a substitute for the Service


Information contained in IMPACT.
Before starting any repair, it is essential that you get the
latest up to date information for the job you are going to
do from IMPACT

Danger, Warning,
Caution & Note

In this guide, risk of injury or damage is indicated by the


following headings:
DANGER - indicates a risk of serious personal injury or
death.
WARNING - indicates risk of personal injury, or severe
product damage.
CAUTION - indicates risk of product damage.
Note - draws attention to special methods or particular
features.

Pay attention to
these headings

Read and implement all DANGER, WARNING and


CAUTION instructions.

Replacement
parts

When replacement parts are required, it is essential that


only Volvo genuine parts are fitted. If Volvo genuine parts
are not used:
- safety features embodied in the vehicle or components
may be impaired.
- performance and/or operation of the vehicle or
components may be adversely affected
- Volvo warranty terms may be invalidated.

Specification

Volvo are constantly seeking ways to improve their


products, and alterations take place accordingly.
Whilst every effort has been made to ensure the
accuracy of this guide, it should not be regarded as an
infallible guide to current specifications of any
particular product.
Neither Volvo, nor the supplier of this book shall, in any
circumstances, be held liable for inaccuracy or the
consequences thereof.

Copyright

All rights reserved. No part of this publication may be


reproduced, stored in a retrieval system, transmitted or
copied without written permission from Volvo Truck &
Bus Ltd.

Volvo Truck & Bus Ltd 2004

Brand image

Brand image

10

Brand image
Company asset

Brand image is an extremely important and valuable asset


for any company. Brand image includes such things as the company name, how that name is styled and presented
- the logostyle - the design, layout and color scheme of
dealer premises, and company vehicle livery.
Brand image is also about what the company stands for,
and how it is perceived by the outside world.

Quality & Safety

Display rules

The Volvo brand image is firmly established and


recognized throughout the world, and is synonymous with
quality and safety, two of the core values of the company.
Volvo applies strict rules on display and presentation of the
brand image - in particular the logostyle.
11

Brand image
Promote the
image

It is in the interest of all representatives of the company including you! to promote and reinforce our brand image at
every opportunity.

Your contribution

You can make your contribution in many ways; here are


just a few:
- be courteous with your customers and colleagues
- work with care and do a quality job
- work with safety in mind - your own and those
around you
- keep your work place clean and tidy

12

Impact

Core values
13

Core values
Quality

Quality work is a fundamental part of all activities,


including:
design development and production. An enormous
amount of energy and expense is committed to ensure that
a quality product leaves the factory - thats why customers
buy them.
sales and service. As a valuable member of the service
team, one of your tasks is to ensure that quality is
maintained throughout the life of the vehicle.
How ? - by doing quality maintenance and repair work.

Focus on
customers

Keep your focus on your customers - they pay your wages !


14

Core values
Safety

Safety applies to:


the product - must be safe to drive and operate. Volvo
are world leaders and innovators of features which make
the product safer for the driver and for others.
the work place - the factory and your workshop. Working
methods must be driven by safe practices and care for
others.
the global view. Volvo takes a worldwide view for the
guidelines on the commitment to safety.

15

Core values

Recycle mark

16

Core values
Concern for the
environment

Volvos concern for our environment takes in the whole


picture - an Holistic view. This includes the effects of:
making the products. The efficient use and selection of
natural resources for the production process, and for
materials used in that process.
using the products - e.g. fuel economy and exhaust
emissions. Volvos extensive research and use of
advanced technology minimizes these effects.
recycling whenever possible, or safe and efficient
disposal of components at the end of their working life.
Volvo products contain many components made from
recyclable materials - recycling marks appear on these
components.
17

18

Impact

19

Impact

20

Impact
On-line resource
centre

Impact is the on-line resource centre for Volvo Truck and


Bus service information.
It contains Service Manuals, bulletins and Parts Catalogues
dating back to 1987.
Data is held on a computer at Volvo HQ in Sweden, and is
constantly updated.
In case of a system failure, Impact is also published on a
DVD.
However, to ensure that you are reading the latest
information, the on-line system must always be your first
choice.

21

open a new job card

Help

open an existing job card


abbreviations
navigator for bulletins and
info.
sniffer dog to search for
info.
navigator for service
manual and parts
catalogue

22

The main icons

Note: Icons become active/inactive dependent on which


screen you are using

23

Impact

IMPACT Logon
User ID:

Password:

Application Language

Britsh English

24

Impact
Note

- Citrix ICA client, & Uniprint must be installed.


- if Impact is left inactive for 1 hour, the system will
automatically log-off.

Log on to Impact

- enter Impact web-site address:


http://impact.vee.volvo.se/
OR
- enter via dealer violin homepage - training- impact.
- ensure Application Language is set to British English.
- enter your User ID & Password.
25

Impact
IMPACT Training 1
File Information Job Card Note Log Help

Other

Displays last 20 places visited


in the session - cleared after
log-off
Personal/public notes can be
added - e.g. part line/number
notes, service information
notes

Other useful
menu
information

Displays latest updates remains for 6 weeks


Click on menu item to open drop-down menus.
26

Impact
Searching for
information

By making the right selections you can search for either


Parts or Service information.
The search basic rules are the same, but the displays differ
slightly.

Chassis
number ?

Example

You can search with or without a chassis number.


If you know the chassis number, and search using the
number, the system will display only the material applicable
to that vehicle.
In the example search which follows, we will search for
Fuel filter - engine.

27

Impact
IMPACT Training 1
File Information Job Card Note Log Help

1
Function Group

233

Model

FH12

2
3

Information Type Parts

All
0 General
1 Service and maintenance
2 Engine, engine mounting and equipment
> 20 General
> 21 Engine
> 22 Lubricating and oil system
> 23 Fuel system
>> 230 General
>> 232 Air cleaner and shutter housing
>> 233 Fuel pump and filter

Retrieval

Parts

Fuel filter, engine


> 2334, 04, FH12, TB-7632157

4
Show

28

Impact
PARTS:
Searching for
information chassis number
NOT known

LH window:
1 Click on Navigator.
2 Enter the model type
3 In Information type select Parts
4 Scroll down the menu until the item you want information
on is highlighted - 2 Engine > 23 Fuel system >> 233 Fuel
pump and filter.
5 Press Retrieval button.
RH window:
6 Open Fuel filter- engine folder.
7 Select vehicle/engine type and specification.
8 Press Show button - parts information now appears.
29

Impact
IMPACT Training 1
File Information Job Card Note Log Help

1
Function Group

233

Model

FH12

2
3

Information Type All Service Information

All
0 General
1 Service and maintenance
2 Engine, engine mounting and equipment
> 20 General
> 21 Engine
> 22 Lubricating and oil system
> 23 Fuel system
>> 230 General
>> 232 Air cleaner and shutter housing
>> 233 Fuel pump and filter

Retrieval

All Service Information

23303-2 Fuel filter, replace (one)


> -FH12, D12C340
> -FH12, D12C380
> -FH12, D12C420
> -FH12, D12C346

4
Show

30

Impact
SERVICE:
Searching for
information chassis number
NOT known

LH window:
1 Click on Navigator.
2 Enter the model type
3 In Information type select All Service Information
4 Scroll down the menu until the item you want information
on is highlighted - 2 Engine > 23 Fuel system >> 233 Fuel
pump and filter.
5 Press Retrieval button.
RH window:
6 Open Fuel filter- replace folder.
7 Select vehicle/engine type and specification.
8 Press Show button - repair information now appears.
31

Impact
IMPACT Training 1
File Information Job Card Note Log Help
6

Job Card 55

Reception Vehicle Service and Parts


Customer Information

5
Vehicle Information
Chassis ID:

Registration No.

KX03AAE

560061

3
4

Country
Fleet No.
Model

FH12

Mileage

32

Impact
PARTS:
Searching for
information chassis number
KNOWN

1 Open a new job card.


2 Select Reception tab.
3 Enter A and the chassis number.
4 Select tick box.
5 Select Vehicle tab for vehicle information.
6 Keeping the job card open, select navigator.

33

Impact
IMPACT Training 1
File Information Job Card Note Log Help

Function Group

233

Model

FH12

Information Type Parts

All
0 General
1 Service and maintenance
2 Engine, engine mounting and equipment

Retrieval

Parts

- accelerator linkage
- cooling system
- engine
- fuel system

Show

34

Impact
7 In information type, select Parts.
8 Press Retrieval button - sub sections now appear in the
RH window.
9 Select fuel system.

35

Impact
IMPACT Training 1
File Information Job Card Note Log Help

FH12 , 23, Parts< FH12 CHID


Parts

Description

Notes

fuel pump

- accelerator linkage
- cooling system
- engine
- fuel system

water separator
fuel filter

11
Retrieval

12
Show

10

36

10 Press Show button - a new window now appears.


11 Select part required - fuel filter.
12 Press Go to button - parts information now appears.

37

Impact
IMPACT Training 1
File Information Job Card Note Log Help
6

Job Card 55

Reception Vehicle Service and Parts


Customer Information

5
Vehicle Information
Chassis ID:

Registration No.

KX03AAE

560061

3
4

Country
Fleet No.
Model

FH12

Mileage

38

Impact
SERVICE:
Searching for
information chassis number
KNOWN

1 Open a new job card.


2 Select Reception tab.
3 Enter A and the chassis number.
4 Select tick box.
5 Select Vehicle tab.
6 Keeping the job card open, select navigator.

39

Impact
IMPACT Training 1
File Information Job Card Note Log Help

Function Group

233

Model

FH12

Information Type All Service Information

All
0 General
1 Service and maintenance
2 Engine, engine mounting and equipment
> 20 General
> 21 Engine
> 22 Lubricating and oil system
> 23 Fuel system
>> 230 General
>> 232 Air cleaner and shutter housing
>> 233 Fuel pump and filter

Retrieval

All Service Information

- 23302-2 Feed pump. replace (Repair 2331)


> 23306-3 Fuel filter, replace (one) (repair 2335)
>> FH12, D12D240
>> FH12, D12D420

11

10

8
Show

12

40

Impact
7 In Information type select All Service Information
8 Scroll down the LH menu until the item you want
information on is highlighted - 2 Engine > 23 Fuel system
>> 233 Fuel pump and filter.
9 Press Retrieval button.

RH window:
10 Open folder - 23306-3 Fuel filter, replace (one)
11 Select model/engine
12 Press Show button - repair information now appears.

41

42

Safe Working Practices


43

44

Safe working practices


The adoption of safe working practices - at all times - is
essential for health and well-being.
Carelessness, or the use of unsafe and unspecified
methods and equipment can endanger your health and
your life and, quite possibly, the health and life of others
around you.
Down to you

Safe working is largely down to you.


Service information can give you the safe methods and
procedures developed and approved by Volvo, and it can
flag-up particular hazards.

Common sense

What it cannot do is put into gear your own common sense,


or instill the need to care and think about what you are
doing at all times.
45

Safe working practices

46

Safe working practices


Your Legal
Responsibility
Safe working

You have a legal responsibility to ensure that:

you work in a safe and careful manner at all times.


Amongst other things, this means - following the Volvo
specified repair procedures and using Volvo specified
equipment.

The right gear

Health & safety


rules

you use the Volvo, or dealer, specified safety clothing


and equipment. The specified clothing and equipment is
likely to differ from job to job.
Make sure you use the right gear at the right time every
time.
you understand the Health and Safety Policy and Rules
in your working environment.
47

Safe working practices

48

Safe working practices


Personal
protection

The following protective items must be worn when needed typical cases are suggested:

safety boots with steel toe caps - all the time.


overalls - all the time.
eye protection goggles - when welding, grinding/cutting/
drilling, working with batteries.

latex gloves - most of the time - especially dealing with


lubricants and fluids, when not wearing other gloves.
cloth gloves - for general handling, when working with:
hot objects, sharp objects, wire rope.
49

Safe working practices

50

Safe working practices


Personal
Protection - cont.

ear defenders - when using, or working near, any noisy


equipment e.g. when grinding/cutting/drilling.

51

Safe working practices

12 volt

+ 24 volt

+
_
+
12 volt

_
Negative earth

Two batteries connected in series


52

Safe working practices


Batteries

Because of the stored electrical energy and electrolyte they


contain, batteries are a special case for safe working. The
following are the main points to note:
- All Volvo trucks and buses have two 12 volt batteries
linked together in series, with negative earth.
Series connection means 24 volts is supplied to the
electrical system.
- Each battery stores up to 190 amps, which represents a
great deal of electrical energy.
- Battery electrolyte is a mixture of water and sulphuric
acid, which is highly corrosive and will cause severe burns
on contact.
- When batteries are being charged hydrogen and oxygen
is produced, and this mixture is highly explosive.
53

Safe working practices

54

Safe working practices


Batteries - cont.

When handling batteries always:


- wear gloves, goggles and overalls.
- ensure that metal tools do not touch both terminals, or a
terminal and bodywork, at the same time. The resulting
sparks will cause severe burns, damage or fire.
- disconnect the negative cable first, connect positive cable
first.

55

Safe working practices


Lubricants and
fluids

56

Safe working practices


Lubricants and
fluids

Harmful

Corrosive

Many different fluids and lubricants are used in vehicles.


These are the main ones:
- engine oil
- manual/auto transmission oil
- axle/differential oil- PAS oil (ATF)
- general purpose grease
- antifreeze
- clutch/brake fluid
- diesel fuel
Most of these are poisonous and harmful to skin, and some
can cause cancer.
Clutch/brake fluid is corrosive and will damage paintwork.
57

Safe working practices


Lubricants and
fluids

58

Safe working practices


Lubricants and
fluids - cont.
Precautions

- drain oils and fluids into suitable containers, and dispose


of safely in accordance with company policy. Clean up
spillage.
- do not mix different makes/types of oils and fluids. Certain
combinations can be dangerous and may cause damage.
- follow makers instructions for the use of products such as
- adhesive, sealer, release agents etc.

59

Safe working practices


Lifting equipment

60

Safe working practices


Lifting
equipment

The main items of lifting equipment you will use are:


- trolley jacks, bottle jacks - almost always used with
wooden blocks, and always used with chassis stands and
wheel chocks.
- vehicle lifts or ramps.
- cranes and hoists.

Safe Working
Load

All lifting equipment has a safe working load (SWL), which


is the greatest weight the equipment can safely support.
Your company must ensure - by law - that all such
equipment is regularly tested for SWL and safety.

61

Safe working practices

62

Safe working practices


Lifting
equipment cont.
Precautions general

- ensure that the vehicle and the lifting equipment are on


firm level ground.
- ensure that the SWL of the lifting equipment - including
chassis stands - is adequate for the load. The vehicle
weight is on a plate inside the drivers door.
- before use, check equipment for damage/cracks/ signs of
stress.

63

Safe working practices

64

Safe working practices


Lifting equipment
- cont.
Precautions jacking

- select a safe location for the head of the jack and chassis
stands
Examples are: chassis frame side/cross members, axles,
hubs.
CAUTION: Do not position a jack or stand under single leaf
taper springs. If the surface is damaged stress points will
develop.
- select wheel chocks which are big enough to prevent
tyres rolling over them. Before lifting, position wheel chocks
at the front and rear of tyres which will stay on the ground.

65

Safe working practices

66

Safe working practices


! WARNING !
Air
suspension

Jacking
procedure

On vehicles with air suspension, air leaks, disconnection of


air pipes, or inadvertent switch operation etc. can cause a
sudden change in chassis frame to axle distance.
To prevent any change, put wooden blocks between the
frame and axles.
1 Chock wheels.
2 Position jack under safe point. If necessary, to ensure
secure fit or to prevent damage, put a wooden block
between jack head and jacking point.
3 Operate jack and raise vehicle to required/sensible
height.
4 Position chassis stand(s) under safe point.
5 Lower vehicle until ALL weight is off the jack and on the
stand(s).
6 Check stand security and stability.
67
7 Remove jack.

Safe working practices

68

Safe working practices


Cab tilt
procedure
Precautions general

- ensure that there is enough space above and in front of


the vehicle to accommodate the tilted cab.
- ensure that people are kept away from the tilt area.
- ensure that there are no loose items in the cab which may
fall during tilting and cause damage.

! WARNING !

All wheels must be fitted and on the ground.


If all wheels are not fitted, the weight of the tilted cab may
overturn the vehicle.

69

Safe working practices

70

Safe working practices


Cab tilt procedure

1 Ensure that the park brake is on and neutral is selected.

Electric tilt

2 Turn the starter switch to radio position.


3 Turn the cab tilt switch to ON position.

Manual tilt

CAUTION
Use ONLY the Volvo supplied bar and socket.
Other tools may not fit correctly on the pump hexagon,
leading to a risk of damage or injury.
4 Remove the cab tilt bar from the side locker, and fit it to
the pump.
5 Turn the pump switch to tilt cab.
6 Operate the pump with the bar.

All models

7 Ensure that the cab tilts as far as possible, and stops.


71

72

Service and Inspection


73

Service and Inspection

74

Service & Inspection


What does
Service mean ?
Planned work

Service means many things but, in this particular instance,


service means:
- pre-planned maintenance work, done at specific
intervals.
Note that this statement excludes repair work, which is the
work necessary to correct a fault or damage. (Except for
minor component changes, such as bulbs, or routine
adjustments).

Unplanned work

Such work is unpredictable and, therefore, unplanned.

75

Service and Inspection


Advantages of
pre-planned
services

- unplanned repairs and breakdowns are minimized. This


means less disruption, less inconvenience, and less cost
for the owner.
- the vehicle is kept in a good condition, which means it is:
safe, reliable, fuel efficient and legal.
It is also more likely to pass the annual MOT with no
problem, and it keeps running longer.
- for the dealer network, pre-planned service work
simplifies workshop planning and job assignment.
Also, providing that you do a good job in the allotted time,
the work is a big money earner.
Good for the dealer - and you !
76

Service and Inspection


Disadvantages of
pre-planned
services

- careless, incorrect or incomplete servicing can cause


other problems, and may result in unplanned repairs.
- those unplanned repairs may have to be paid for by the
dealer - your employer.
Not good for them - or you !

77

Service and Inspection


Types of service

To be able to offer efficient and economic service


plans to suit the needs of many different operating
environments, eleven service types have been
developed:
- Intermediate Service
- Lubrication only
- Basic Service
A, B
- Major Service
A, B, C, D, E, F, G
78

Service and Inspection


Which Type of
Service - and
when ?
Volvo Service
Program

With so many operating conditions and eleven different


possible services, its important to keep track of the history
to be able to plan future servicing patterns.
Fortunately, Volvo has developed an automated service
planning program.
When the details of a vehicle, and its operating conditions,
are first entered, the program automatically works out a
service planning matrix.
When a service is due, the correct service sheet is
generated.

79

Service and Inspection

Volvo PM Service Inspection Protocol 1.2


Dealer

ABC Truck & Bus

Date

19/03/04

Customer

Commercial United

RO No.

WAR 1200AM

Address

123 Road

Reg. No. T100 ABC

Town

XYZ

Kms

30,000

County

Warwickshire

Country

ENGLAND

Volvo Trucks

Model Select

FM12

Engine Select D12D

Intermediate Service

Customer & vehicle details

80

Service and Inspection


Service sheets

1 Customer
and vehicle
details

Completion is
important

Service sheets can be divided into five main areas. The


first area is at the top of the sheet.

If the vehicle details are in VOSP, all the details will be


printed out - except current mileage.

It is important that these details are correctly entered to


ensure:
- records are correct and up to date.
- the correct VSTs are applied.
- warranty claims are not rejected.
- invoices are correct.
- a professional approach is apparent.
81

Service and Inspection

Check & Report on Function Condition &


Security of the items below

Testers
Manual No.

Check number

Judgement codes ( ) Serviceable - (S) Safety related repair required - (R) General repair recommended - (O) Observe condition or performance

General round vehicle & inside cab checks


1 Fault codes
2 W/sceen wipers, washers incl. h/lamps

(25)

3 Electrical wiring & Equipment

(42)

Instrument illumination

Ventilation, defroster, AC & Heaters

Audible Warning (Horn)

Seat & Seat Belts

(27)
(18/3)

82

Service and Inspection


2 The inspection

All the checks to be done at this service are listed and


numbered.

Function Group
17

Details of how the checks should be carried out are located


in Function Group 17.

MOT Testers
Manual

If a reference number appears in the column Testers


Manual No. the check is part of the annual MOT.
The number cross-refers to the appropriate section in the
Testers Manual, where additional information will be found.

83

Service and Inspection

84

Service and Inspection


Judgement codes

ALL Judgement code boxes must be marked with the


appropriate code:
X = Serviceable, no fault found.
S = Safety related defect e.g. it would fail an MOT, or it is
illegal.
R = Repair recommended e.g. it is outside Volvo tolerance.
O = Observed worn/damaged, but still within Volvo
tolerance.

3 Lubrication

Details of how lubrication should be carried out, and


lubricant and fluid specifications, are located in Function
Group17.

85

Service and Inspection

86

Service and Inspection


4 Measuring

The Service sheet has boxes for recording the following


measurements:

- wheel nut torque.


- tyre tread depth and tyre pressure.
- brake lining thickness, lever travel and brake performance
test results.
- clutch wear.
Measuring
equipment

To ensure accurate results, it is essential that all measuring


equipment is in good condition, and accurately calibrated.
87

Service and Inspection


4 Measuring
- tyres

37. Tyre Depth (7/8)

O/S

N/S

37. Tyre Pressure


(7/8)

O/S

N/S
88

Service and Inspection


4 Measuring
- tyres

Boxes are provided to record the tread depth and tyre


pressure of 8 rear tyres and 4 front tyres - i.e. an 8 x 4.
For a 4 x 2, front boxes and 4 rear boxes should be used.

89

Service and Inspection


4 Measuring
- brakes
78. Brake test overall result (71, 72, 73)

Service (71)

Sec (72)

Park (73)

50%

Service Brake footbrake


90

Service and Inspection


4 Measuring
- brakes

GVW axle
weights

Service brake
test
(footbrake)

Note: If brake performance figures are not entered on the


Service sheet, the vehicle cannot be considered
roadworthy.
Record the GVW axle weights from the chassis plate inside
the drivers door i.e. NSF, OSF, NSR, OSR.

Minimum acceptable values are:


- Vehicle 50% Gross vehicle Weight (38 - 44 tonne)
- Semi-trailer 45%
- Drawbar 45 %
91

Service and Inspection


4 Measuring
- brakes
20
4
10 2

0000 kg
00 %
0

30

0 Brake force 8
x 100 kg
40

Print Another
Test Report ? (Y/N)
92

Service and Inspection


4 Measuring
- brakes
Brake
efficiency

Example

Efficiency = total axle weights kg/GVW kg x 100.

What is the efficiency if GVW is 28000 kg?


Total axle weights: NSF 2000kg + OSF 2000 kg +
NSR 5000 kg + OSR 5000 kg = 14000 kg
14000/28000 = 0.5
0.5 x 100 = 50%
93

Service and Inspection


4 Measuring
- brakes
78. Brake test overall result (71, 72, 73)
Service (71)

Sec (72)

Park (73)

25%

Secondary
Brake
94

Service and Inspection


4 Measuring
- brakes
Secondary
brake test

The secondary brake test will vary depending on the type


of vehicle.
Generally the secondary brake is applied using the first
stage operation of the park brake control valve, this will
apply the spring brakes on all axles where spring brakes
are fitted. The efficiency of the secondary brake should be
25% of GVW (this is calculated in exactly the same way as
the service brake).

On FL6, which has a single function park brake control, the


secondary brake can not be applied independently.
Therefore the efficiency is calculated from the individual
performance of the service brakes on the front and drive
axle, each must produce an efficiency of at least 25%
95

Service and Inspection


4 Measuring
- brakes
78. Brake test overall result (71, 72, 73)
Service (71)

Sec (72)

Park (73)

16%

Park Brake

96

Service and Inspection


4 Measuring
- brakes
Park brake
test

Minimum acceptable values are:


- 16% of GVW
- 12% Gross Train Weight (GTW) if type approval
certificate.

97

Service and Inspection


1
(9988698)

<

X2

>

X1
X2
98

Service and Inspection


4 Measuring
- clutch

Note: On IShift transmissions there is no hole in the bell


housing. VCADS Pro Clutch Test 40010-2 must be used for
IShift.

Non - IShift

1. Insert tool (1) into the hole in the bell housing, with guide
flange (2) held against the housing.
2. Push bar (3) through the guide until it contacts the clutch
release fork.
3. Holding the bar and guide together, so that their relative
positions cannot change, remove the tool.
4. Measure distance X2.

99

Service and Inspection


SB411 - 18
SB411 - 20

X1

X2

100 mm

105 mm

mm

14/010/03

100 mm 1

137 mm

37 mm

14/010/04

100 mm 2
mm 3

Clutch record label - Example only


X1 = measurement - new plate
X2 = measurement - plate with wear
Y (wear) = X2 - X1
Y max. single disc = 34 mm. Y max. double disc = 36 mm.
100

Service and Inspection


4 Measuring
- clutch

5. Write the measurement under X2.


6. Compare with measurement for a new plate under X1.
7. Write wear value under Y.
8. Write date under D.

101

Service and Inspection


5 Recording
defects
Volvo PM Service Inspection Protocol 1.2

Volvo Trucks

Defect Report Sheet

The following should be carried out


(subject to Judgement Codes)

18 S NS Headlamp inop

Repair Description

Renew bulb

Standard Times
Number

Judgement Code

Number

Confirmed Defect Description

3513

Completed

Initials

DS

102

Service and Inspection


5 Recording
defects

A Defect Report Sheet is provided to log details of defects


noted on the Service Sheet.
All noted defects must be logged, and must match
comments on the Service Sheet.

Exceptions to
signing the
declarations

If you are unable to do any of the checks - e.g. if the brake


tester is not working, so that the brake test cannot be done,
there is no way of knowing if the vehicle is safe and
roadworthy.
In such cases neither declaration can be signed.

Disclaimer

If you find a defect, but the customer wants to do the repair


himself, you must ensure that Service Reception are aware
of this, and that the customer provides a written disclaimer.
In such cases the rectification declaration cannot be
signed.
103

Service and Inspection


6 Signatures
Declaration (Inspection)
We certify that this vehicle has been inspected and serviced in
accordance with Volvos current recommendations and DoT vehicle
Inspectorate Testers Manual and that all applicable items have been
checked and found serviceable except as noted on the defect sheet.
Signature .........................................................................Technician
Print Name .......................................................................Technician
Checked by ........................................................ Supervisor/Manager
Print name ..........................................................Supervisor/Manager
104

Service and Inspection


6 Signatures
Declaration (Rectification - as noted on Defect Sheet)

I certify that codes S


on the Defect Sheet.

defects have been rectified as initialled

Signature .........................................................................Technician
Print Name .......................................................................Technician
I certify that the Service indicated above has been completed &
codes S
R
defects have been rectified and that in my opinion the
vehicle is in a safe and roadworthy condition.
Signature ........................................................

Supervisor/Manager

Print name ..........................................................Supervisor/Manager


NB Declaration must not be signed if S code defects are not rectified

105

Check & Report on Function Condition &


Security of the items below

Testers
Manual No.

Service and Inspection

General round vehicle & inside cab checks


1 Fault codes
Cross reference
from Service
Sheet to
Vehicle
Inspection
Manual

2 W/sceen wipers, washers incl. h/lamps

(25)

3 Electrical wiring & Equipment

(42)

Instrument illumination

Ventilation, defroster, AC & Heaters

Audible Warning (Horn)

Seat & Seat Belts

(27)
(18/3)
106

Service and Inspection


Vehicle
Inspection
Manual example
only

25

Heavy Goods Vehicle Inspection Manual


Windscreen wipers and washers
Application
This inspection applies to all vehicles except those with an opening
windscreen or where an adequate view can be obtained by some other
means.
Procedure and Standards
Check the operation of the wipers and washers.
Wipers must be able to clear an adequate area of the screen to give the
driver a view of the road to the front and in front of both sides of the
vehicle.
Reasons for failure
1 Switches missing or defective.
2 Wipers: a. do not move over an adequate area - b. do not work
continually when switched on - c. blade missing, insecure, or so
deteriorated that it cannot clear screen effectively.
3 Washers: ineffective.

107

108

Service and Inspection


Service
Process

So that you use your time to best effect, and are able to
meet VST for services, it is essential that you carry out the
complete service process in a logical and efficient manner.
The following sequence is recommended:
1 Check job description on job card.
2 Inspection.
3 Inform service reception about any major faults.
4 Lubrication.
5 Brake test.
6 Test drive.
7 After test drive checks.
8 Clean vehicle and report completion to service reception.
109

Service and Inspection

Start

110

Service and Inspection


Inspection
Procedure

Note: If any faults are found during the inspection, make a


note of them on the service defect sheet.
1 Inside cab - check numbers 1 - 12.
2 Starting at drivers door, work round the vehicle - check
numbers 13 - 45.
3 Tilt cab - observe safety precautions.
4 At ground level, inspect engine area, underside of cab
and cab exterior - check numbers 46 - 77
5 Go under vehicle.
6 Mentally divide the vehicle into sections. Starting at the
front inspect each section - check numbers 31 - 77.
7 Report any major defects to Service Reception.
8 Carry out lubrication procedure.
111

Service and Inspection


Lubrication
Procedure

Note: Refer to the correct lubrication chart for lubricant


specifications, and locations.
At each grease point look for movement of old grease
around the joint. Movement indicates that new grease has
entered the joint.
Under the vehicle:
Starting at the front and working towards the rear, lubricate
all points shown on the chart.
Ground level:
Starting at the rear and working towards the front, lubricate
all points shown on the chart - including trailer coupling,
cab pivots/hinges.
Under cab:
Tilt cab - observe safety precautions.
Starting at the rear of the engine and working towards the
front, lubricate all points shown on the chart
112

Service and Inspection


Lubrication
Procedure

Oil and filters


Under the vehicle:
Drain oil - engine, gearbox, differential, other components.
Renew filters - engine oil, fuel.
Under cab:
Tilt cab - observe safety precautions.
Renew any filters not reached from below - engine oil, fuel.
Bleed the fuel system.

113

Job Card
Customer

Vehicle Reg.

RO Number

Technician

Description

Chassis No.

Mileage

Time

114

Completing the
Job Card

What is written on the job card is very important.


Cost/warranty/ invoice staff get information from the card to
pass on to the customer, and to issue invoices.

To ensure that other people can understand the checks and


work that you have done, your writing style is important.
Two hints to
remember

- A, B, C Your style should be: Accurate - Brief Concise - compare the examples.

- Three Cs - Complaint - Cause - Corrective action


Complaint

Example OK

What is the customers complaint or problem ?

Customer complained that the head lights were faulty


115

Cause

Understand the cause - whats wrong ?


First, confirm for yourself that the headlights are faulty, then
find the cause of the fault.

Example OK

Found headlights faulty due to chafing in wiring harness


which caused fuse and bulb to blow.

Example not
OK

Went to get keys from reception, then went out to the yard
to bring vehicle in. Geoff operated the stalk in the cab while
I checked the lights outside. Then I found that the bulbs did
not work so I replaced the bulbs.
The bulbs still did not work so I went to my tool box for a
multimeter to check for 24 volts ....................

116

Corrective
action

Repair the fault, then ensure that the headlights now work
correctly.

Example OK

Repaired wiring harness, and replaced fuse and bulb.


Lights now operate to correct specification.

Example not
OK

I went to the parts store to get a wire joint sleeve. Then I


went to my tool box to get some wire crimps. I cleaned the
broken wire, then repaired it with the joint sleeve. Then I
went to the parts store for a fuse and bulb.
Then I replaced the fuse and bulb ...............

117

Notes

118

Notes

119

Notes

120

Notes

121

Notes

122

123

124