Preventive maintenance

TUJUAN DARI PELAKSANAAN TRAINING

PREVENTIVE MAINTENANCE :

setelah mengikuti Training para peserta diharapkan :

1.Mampu menggunakan alat dan metode yang

benar sesuai dengan service literatur

2. Mampu melakukan pengukuran, penyetelan dan setting pada Truck

dan komponent komponent utamanya.

3. Mampu melakukan service perbaikan secara spesifik dengan

berpedoman pada program yang Ada pada Volvo preventive
maintenance
Preventive Maintenance

 Truck’s always ready for use

 Earlier Investigation
 Monitoring problem had being happen
 Long life Component
 Reduce cost
 Reduce breakdown time
 The most common quality designations for engine
oil used in Volvo trucks ( standar pengukuran
mutu pelumasan ):

1. (VDS3, VDS2, VDS),

2. (ACEA E2, E3, E4, E5),
3. (API CF, CF-4, CG-4, CH4 or
CI-4)

Note :
VDS : Volvo Drain Specification
ACEA: Association Constructeurs Européens d'Automobiles
API :The American Petroleum Institute

viscosity grades recommended by Volvo for engine oil

(standar tingkat kekentalan oli pelumas ):
Note :
SAE 10W-30, 10W-40, 15W-40 Dst
SAE: Society of Automotive Engineer
Type of Engine
 VOLUME OLI ENGINE DALAM LITER

TYPE OLI PELUMAS: SAE 15W/40 API CF,CF-4,CH-4,CI-4

JUMLAH OLI PELUMASL

TYPE ENGINE JUMLAH OLI PELUMAS MIN/MAX
PADA DIPSTIK

D9A 28 LITER 6 LITER

D9A OILS-ST 33 LITER 5 LITER
D9B 33 LITER 5 LITER
D12 C 33 LITER 6 LITER
D12 D OILS-ST 38 LITER 12 LITER
D12 D OILS- PS 33 LITER 9 LITER
D16 A/B 42 LITER 9 LITER
D16 C 42 LITER 9 LITER
D13A/B OILS-ST 37 LITER 6 LITER
D13A/B OILS-PS 33 LITER 8 LITER
TYPE AIR PENDINGIN DAN JUMLAHNYA PADA
MASING MASING ENGINE/TRUCK
TYPE ENGINE/TRUCK VOLUME DALAM LITER
D9A FM9/D9B FM 37 liter
D12 FH12/D13 FH 44 liter
D12 FM12/ D13 FM 42 liter
D16 52 liter
TYPE ENGINE TYPE AIR PENDINGIN
D12 C ANTI RUST
D12 D ETHYLENEN GLYCOL
D13 A VCS
D13 B VCS
D9 A VCS
D9B VCS
D16 A ANTI RUST
D16 B ANTI RUST
D16 C VCS
Type of Gearbox
 Jenis oli Transmissi & Volume berdasarkan type
Transmissi
Type Gearbox Jenis Oli Pelumas Volume oli dalam liter

VT2014; VT2214B;
VT2514OD, VTO2214B, 13,5 liter
VTO2514B,VTO2814B SAE 50
SINGLE GRADE
VT2009B API CE or CF 12.0 liter
ACEA E2 or E3
VT2412B 13.0 liter

VT1605PT, VT1705PT ,
VT1706PT , VT1805PT ATF DextronIII &
Alison C4 35 liter
VT1906PT , VT2006PT ,
VT2206PT , VT2506PT
Note : Oli Manual Transmissi diganti setiap 20.000 km
Oli Auto Transmissi diganti setiap 40.000 km
Type of Final Drive
Jenis oli pelumas pada Rear axle
TYPE REAR AXLE JENIS OLI PELUMAS VOLUME DALAM LITER

EV72 - front 28,0 LTR

CTN372
EV71 - rear 28,0 LTR
SAE 140
GL-5
Front axle SINGLE GRADE 22,5 LTR
RT3210HV
Rear axle 18,5 LTR

NOTE :GANTI OLI DIFFERENTIAL SETIAP 20.000 KM

 Type oli pelumas dan jumlah oli pada Hub
Reduction
Jumlah Oli Untuk setiap
Type Rear axle Type Oli hubnya

CTN372 (front axle) 3 ltr

CTN372 (rear axle) 3 ltr

RT3210HV (front axle) SAE 140 3 ltr

RT3210HV (rear axle)
SINGLE GRADE 3 ltr

RT3210HV (rear axle) 1 1,5 ltr

RT3210HV (front axle)1 1,5 ltr

1 The oil volume is 1.5 litres only for hub reduction

covers with part numbers 1524851 or 1524852. This
marking can be seen on the hub reduction covers
 1. Chassis Lubrication

•
lubrication chart

A Lubrication points

B Fluid level checks

C Oil and filter change

Lubrication Chart Legend

1. Engine Oil
2. Gearbox Oil & Engine Oil
3. Rear Axle Oil
4. ATF Oil
5. Hydraulic Oil
6. Brake & Clutch fluid
7. Grease
2. Cab lubrication
3. Change engine oil and filter
Oil Level
FM/FH series
5. Check oil level in manual gearbox
6. Change Gearbox oil and filter
7. Check oil level in rear axle
8. Change oil Rear axle
9. Check oil level in Power steering
10. Filter change in power steering
11. Check oil level hub reduction
12. Change oil in hub reduction
13. Check oil level in cab tilt pump
14. Check fluid level in clutch fluid
reservoir
15. Check coolant frost protection and
fluid level
16. Check fluid levels in windscreen and
headlamp washer reservoirs
17. Check air drier
18. Check warning and control lamps
19. Check fault codes in the vehicle
control units
21. Check gear shift linkage and clutch
pedal
22 Check retarder controls
24. Check pressure regulator cut-out
and cut-in pressure
25. Check compressor function and
condition
26. Check pressure drop in compressed
air system
27. Check parking brake and
blocking valve
28. Check brake pedal and foot brake valve
29. Check hinges, door stops, locks and
sealing strips
30. Check lighting and reflectors
32. Check condition of wipers and washers
33. Check batteries — dirt, leakage, attachment,
fluid level, connections and battery box
34. Check fuel tank, hoses, pipes, venting and
mounting
35. Check fuel tank ventilation filter
36. Check tyre wear
37. Check of receiver dryer tank, condenser,
pipes and hoses
38. Check alternator mounting, electrical
connections and cables for alternator, starter
motor and preheating unit
39. Check drive belts and belt tensioners
40. Check radiator fan, bearing tolerance,
screw unions, fan shroud and fan ring with
rubber seal
41. Check engine mounting
42. Check radiator, hoses, pipes and air
through-flow
43. Check fuel pipes and lines
44. Check for exhaust leakage
 45. Check intercooler, hoses, pipes and air
through-flow

.
46. Check air pipe between air intake and
turbo

Rubber Valve
47. Check turbocharger and regulator
50. Check sealing on servo pump, oil
connections, oil hoses and steering gear
51. Check Gaiters and Clearance Ball Joints
52. Check steering link system
53. Check front shock absorbers
54. Check steering knuckle bearing
55. Check front wheel bearings
56. Check front wheels
57. Check slack in mechanical linkage
for clutch
58. Check ventilation for gearbox,
transfer gearbox and PTO
 59. Check the sealing on the gearbox, transfer gearbox and
power take-off and check of cables and wire controls

 Check that the gearbox, manual or automatic, does not leak oil or coolant.
 Check that pipes and hoses for oil cooler are secure and not leaking.
 Check that the power take-off or transfer gearbox does not leak oil.
 If leakage, check the oil level.
 Check that there is no air leakage from components or compressed air pipes.
 Check that electrical connections, electric cables and compressed air connections on the
gearbox are secure and not chafing.
 Check that the wire controls between the gear lever and the gearbox are not damaged and are
secure
60. Check clutch hydraulic and pneumatic
control system
61. Check clutch wear
63. Check the seal on the speedometer
66. Check springs and u-bolts
65. Check bearing clearance in the pinion
and rear axle input shaft
67. Check sealing of rear axle and hub
reduction
68. Check propeller shafts – universal joints,
sliding joints and support bearings
69. Check exhaust pipe and silencer or
particulate filter
70. Check brake linings
71. Check brake cylinders, levers and forks
72. Check brake lever travel
73. Check anti-roll bar
74. Check rear shock absorbers
75. Check front and rear axle suspension
76. Check chassis frame and cross members
77. Check compressed air lines and
hoses
79. Check rear wheel bearings
Change air filter for A/C and check roof-
mounted A/C
Check air intake and air deflector
Check cab anchorage, hydraulic system,
locking devices, grille and cab tilting
Check AC—compressor for climate
control system
V-stay, axial play, check
 80. Check after start
 Check that the position of the steering wheel can be adjusted in height and in length. Check that the steering wheel is
locked in the set position.
 Check that the warning lamps, indication lamps and instruments function.
 The oil pressure and charge warning lamps should go out as soon as the engine is started. Check that the engine oil
pressure gauge shows oil pressure.
 The symbol or warning lamp for low coolant should be extinguished.
 The symbol or warning lamp for cab locking should go out, which indicates that the cab is properly locked.
 The warning lamp for the pusher axle and trailing wheel axle hydraulic steering system should go out.
 Warning lamps for service brakes should be extinguished when the compressed air system is charged.
 The parking brake warning lamp should go on when the parking brake is applied.
 The check lamp for anti-lock brakes (ABS) should light up.
 Check the centring function of the hydraulically steered pusher axle or hydraulically steered trailing wheel axle:
 Turn the wheels to one side (front axle, pusher axle or trailing wheel axle wheels).
 Switch off the engine.
 Turn the ignition key to the start position, and check at the same time that the pusher axle or trailing wheel axle
wheels do a centring movement.
 When the front axle wheels are turned to the straight ahead position, the pusher axle or trailing wheel axle wheels will
start to turn in the opposite direction. When the front axle wheels approach the straight ahead position, the pusher
axle or trailing wheel axle wheels will centre. After this, the steering lock of the two axles will track each other.
 Note: The centring function is a safety function and should always be checked. If you are not sure about the centring
function of the pusher axle or the trailing wheel axle, see Service Information group 6.
 Note: The information lamp and the symbol which warns of low air pressure in the air suspension system should be on
when driving.
 Note: Never start driving as long as the warning lamps for the brake system or the warning lamp for the parking brakes
are lit.
 81. Check during road test
 Ensure that the speedometer/tachograph, odometer and other instruments are in working order.
 The brake system air pressure gauges should be within the limits for normal values.
 Check that the vehicle can be steered satisfactorily and without imbalance.
 Check that the brakes function correctly and do not pull to one side or grab.
 Check that the exhaust brake is working correctly.
 Note: On the D12 engine, the engine must be warmed up before the VEB (Volvo Engine Brake) will work.
 Check that the retarder functions correctly. Apply the retarder cautiously.
If the oil has been changed in the compact retarder, drive at an approximate speed of 50 km/h. Apply
the retarder 5 times at position 2 for about 5 seconds each time.
 Listen and attempt to assess whether there is any exhaust leakage during loading.
 Check that the symbol or the warning light for the blocked air cleaner does not light up when driving.
 Check that the clutch and gearbox, manual or automatic, function correctly.
 Check that the differential locks and engagement of front wheel drive, plus the appropriate indication
lamps function correctly.
 Check that the engine has the correct working temperature (at least 75°C).
 Check that the heating system and climate unit function.
 Check when driving that the windscreen wiper functions and that the swept area is correct.
 Check when driving that the windscreen washer functions and that the jets are correctly aimed.
 82.Check after road test

 Check parking brake application by attempting to let the truck pull away gently with the parking brake
applied.
 Check that the power take-off re-engagement interlock functions. If the engine is shut off with the
power take-off engaged, the power take-off is disengaged. When the engine is restarted, the power
take-off is disengaged although the switch is in the on position.
 Listen for abnormal sounds from the engine bay.
 Check that the exhaust pipe and silencer joints seal correctly.
 If the vehicle is fitted with an automatic gearbox a final check of the oil level should be made when the
gearbox is warm after the test drive.
 Apply the parking brake.
 Put the gear selector in neutral with the engine running at about 1000 rpm.
 Wipe the dipstick on a clean lint-free paper.
 Check the oil level on the dipstick.
 Drain off or top up with new oil if necessary. Be especially careful with the cleanliness of the oil.
Dirt in the oil can damage the gearbox.
 Check the display to see that there are no error codes stored in the vehicle's control units. Use the
appropriate service information to help rectify any error codes.
 Check that there is no oil or fluid leakage.
 83. Finish

 Wipe off handles, steering wheel and controls.

 Wipe off the floor matting.
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