TRAINING TIPS & TACTICS
Module 1- foundation
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Contents Brand image Core values Impact Safe working practices Service and Inspection
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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
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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.
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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.
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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.
c
Volvo Truck & Bus Ltd 2004
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Brand image
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Brand image
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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
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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 - that’s 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.
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Core values
Recycle mark
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Core values Concern for the environment
Volvo’s 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. Volvo’s 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
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Impact
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Impact
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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.
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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
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The main icons
Note: Icons become active/inactive dependent on which screen you are using
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Impact
IMPACT Logon User ID:
Password:
Application Language
Britsh English
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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’.
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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
5
Parts
Fuel filter, engine > 2334, 04, FH12, TB-7632157
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7
4 Show
8
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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
5
All Service Information
23303-2 Fuel filter, replace (one) > -FH12, D12C340 > -FH12, D12C380 > -FH12, D12C420 > -FH12, D12C346
6
7
4 Show
8
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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
1
Job Card 55
2
Reception Vehicle Service and Parts Customer Information
5 Vehicle Information Chassis ID:
A
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.
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Impact IMPACT Training 1 File Information Job Card Note Log Help
Function Group
233
Model
FH12
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Information Type Parts
All 0 General 1 Service and maintenance 2 Engine, engine mounting and equipment
Retrieval
8
Parts
- accelerator linkage - cooling system - engine - fuel system
Show
9
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Impact 7 In information type, select ‘Parts’. 8 Press ‘Retrieval’ button - sub sections now appear in the RH window. 9 Select ‘fuel system’.
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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
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10 Press ‘Show’ button - a new window now appears. 11 Select part required - ‘fuel filter’. 12 Press ‘Go to’ button - parts information now appears.
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Impact IMPACT Training 1 File Information Job Card Note Log Help 6
1
Job Card 55
2
Reception Vehicle Service and Parts Customer Information
5 Vehicle Information Chassis ID:
A
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.
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Impact IMPACT Training 1 File Information Job Card Note Log Help
Function Group
233
Model
FH12
7
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
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All Service Information
- 23302-2 Feed pump. replace (Repair 2331) > 23306-3 Fuel filter, replace (one) (repair 2335) >> FH12, D12D240 >> FH12, D12D420
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10
8 Show
12
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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.
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Safe Working Practices 43
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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
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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
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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
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Safe working practices Personal Protection - cont.
♦ ear defenders - when using, or working near, any noisy equipment e.g. when grinding/cutting/drilling.
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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
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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.
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Safe working practices Lubricants and fluids
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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
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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.
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Safe working practices Lifting equipment
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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.
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Safe working practices
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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 driver’s door. - before use, check equipment for damage/cracks/ signs of stress.
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Safe working practices
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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.
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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.
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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
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Service and Inspection 73
Service and Inspection
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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.
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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 !
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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, it’s 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 it’s 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.
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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
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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 VST’s 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)
4
Instrument illumination
5
Ventilation, defroster, AC & Heaters
6
Audible Warning (Horn)
7
Seat & Seat Belts
(27) (18/3)
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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.
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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.
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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 driver’s 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
6
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)
2
3
<
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
Y
D
100 mm
105 mm
5
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 Volvo’s 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.
R
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)
4
Instrument illumination
5
Ventilation, defroster, AC & Heaters
6
Audible Warning (Horn)
7
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.
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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
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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 driver’s 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.
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Job Card Customer
Vehicle Reg.
RO Number
Technician
Description
Chassis No.
Mileage
Time
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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 C’s - Complaint - Cause - Corrective action Complaint
Example OK
What is the customer’s complaint or problem ?
Customer complained that the head lights were faulty 115
Cause
Understand the cause - what’s 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 ....................
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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 ...............
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Notes
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Notes
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Notes
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Notes
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Notes
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