Competence Development Planning

Preventive maintenance

Training Department
Training Division
TST 1701-1, March 2010
Competence Development Planning
 Competence Development Planning

Preventive Maintenance
 Truck selalu siap digunakan
 Investigasi awal
 pemantauan Masalah yang
akanterjadi
 umur Komponen Panjang
 mengurangi biaya
 Mengurangi waktu
breakdown
 Competence Development Planning

Financial Services

Volvo Construction Equipment

Volvo Aero

Volvo Penta Volvo Bus

Mack Renault Trucks Volvo Trucks

Training Division
TST 1701-1, March 2010
 Competence Development Planning

FM9, & FM12

F Forward built cab

M Medium height instep
9, 12 Engine displacement in litres

FH12, FH16

F Forward built cab

H High height instep
12, 16 Engine displacement in litres

Training Division
TST 1701-1, March 2010
 Competence Development Planning

Training Division
TST 1701-1, March 2010
 Competence Development Planning

VIN
VIN
1. Place of Manufacture
2. Type of cab
3. Engine type
4. Brakes/ axle combination
5. Check sum
VIN 6. Model year
7. Assembly factory
8. Chassis serial number
 Competence Development Planning

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
Training Division
TST 1701-1, March 2010
 Competence Development Planning

Type of Engine

D 13 A
 Competence Development Planning

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
D11A/B OILS-ST 37 LITER 6 LITER

Penggantian setiap = 10.000 km

Competence Development Planning

TYPE AIR PENDINGIN DAN JUMLAHNYA PADA

MASING MASING ENGINE/TRUCK
TYPE ENGINE/TRUCK VOLUME DALAM LITER
FM 11 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
D11 A VCS
D9A/B VCS
D16 A ANTI RUST
D16 B ANTI RUST
D16 C VCS
Competence Development Planning

Type of Gearbox

AT 24 12 C
Generation
Forward gear
Max. Torque 2400 Nm
Automatic Transmission
 Competence Development Planning

Jenis oli Transmissi & Volume berdasarkan type Transmissi

Type Gearbox Jenis Oli Pelumas Volume oli dalam liter

VT2014; VT2214B;
VT2514OD, VTO2214B,
VTO2514B,VTO2814B 13,5 liter

VT2009B
SAE 50 12.0 liter
VT2412B SINGLE GRADE 13.0 liter
AT2412C, AT2412D, API CE or CF
AT2512C, ATO2512C, ACEA E2 or E3
AT2612D, ATO2612D,
AT2812C, AT2812D, 16 liter
ATO3112C, ATO3112D,
ATO3512D
ATF DextronIII &
VT1605PT, VT1705PT , Alison C4 35 liter
VT1706PT , VT1805PT
Note : Oli Manual Transmissi dan I-shift diganti setiap 20.000 km
Oli Auto Transmissi / powertronic diganti setiap 40.000 km
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Type of Final Drive

 Competence Development Planning

Jenis oli pelumas pada Rear axle

TYPE REAR AXLE JENIS OLI PELUMAS VOLUME DALAM LITER

`front 21,0 LTR

RTH3312
rear 17,5 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

 Competence Development Planning

Type oli pelumas dan jumlah oli pada Hub

Reduction
Jumlah Oli Untuk setiap
Type Rear axle Type Oli hubnya

RTH3312 (front axle) 3 ltr

RTH3312 (rear axle) SAE 140 3 ltr

RT3210HV (front axle) SINGLE GRADE 3 ltr

RT3210HV (rear axle)
Atau 3 ltr
SAE 85W-140

NOTE :GANTI OLI DIFFERENTIAL

SETIAP 20.000 KM
Competence Development Planning

Cab lubrication
Lubrication point Lubricant

1. Lock and hinge Grease, oil

2. Upper foot step Oil

3. Lower foot step Oil

4. Door stop Grease

5. Key hole Lock oil

6. Lock tongue, striker plate Paraffin wax

7. Lock, baggage hatches Paraffin wax

8. Cab lock Grease

Competence Development Planning

Change engine oil and filter

Competence Development Planning

Oil Level
FM/FH series
Competence Development Planning

C
Competence Development Planning
Ganti oil Filter
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Check oil level in rear axle

Change oil Rear axle

Clean round the

level/filler plug (A).

80 ± 20 Nm
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Check oil level in Power steering

Filter change in power steering

Filter Change : 1000 Hm

Competence Development Planning

Check oil level hub reduction

Change oil in hub reduction
Competence Development Planning

Check oil level in cab tilt pump

 Competence Development Planning

Training Division
TST 1701-1, March 2010
Competence Development Planning

Check coolant frost protection and fluid

level

1000 Hm / 500.000 Km
Competence Development Planning

Check fluid levels in windscreen and

headlamp washer reservoirs

•Top up with washer fluid

as necessary.
Competence Development Planning

Check air drier

 Competence Development Planning

Calibrating the air dryer

- saat penggantian air dryer,filter atau compressor harus dilakukan kalibrasi

- saat penggantian air compressor dengan ukuran yang berbeda parameter data harus dirubah
Frekuensi regenerasi dapat dirubah,selama type penggeraknya berbeda,semua calibrasi dan untuk
merubah hasil parameter data Dilakukan oleh V-cads pro

Training Division
TST 1701-1, March 2010
Competence Development Planning

Replace Air drier

 Competence Development Planning

11 = Inlet from the compressor

12 = External air input
21 = Outlet service brake circuit front axle
22 = Outlet service brake circuit rear axle
23 = Outlet trailer brake circuit
24 = Outlet clutch and gearbox
25 = Outlet air suspension
26 = Outlet auxiliary devices
27 = Control signal for compressor
28.1 = Outlet parking brake 1
28.2 =Outlet parking brake 2
29.1 = Outlet parking brake trailer not braked
29.2 = Outlet parking brake trailer braked
31 = Main exhaust, silencer connection
32 =Parking brake relay valve exhaust
33-38 = Secondary exhausts
4.2 = Control inlet service brakes
 Competence Development Planning

Instrumentation

> IC
> SID
Training Division
TST 1701-1, March 2010
 Competence Development Planning

Check warning and control lamps

1. Focus change between navigation in the driver information display or the secondary display.
2. Navigate left.
3. Escape (cancel/go back).
4. Navigate right.
5. Navigate up/down. Confirm selection/OK (press).
Competence Development Planning

Diagnostics
 Competence Development Planning

Training Division
TST 1701-1, March 2010
 Competence Development Planning

Check retarder controls

•Check that the control steps are distinct and that the control remains in the set position.

Check that the control springs back to bottom position.

 Competence Development Planning

Check parking brake

Apply Parking Brake Release Parking Brake
Competence Development Planning

Check lighting and reflectors

A. Position lights.
B. Day Running Light.
C. Dipped beam/main beam.
D. Main beam and auxiliary
lamps(spotlights).

1. Instrument lighting day/night, presets.

Press the scroll wheel.
2. nstrument lighting, dimmer.
3. Light switch.
4. Fog light rear.
Competence Development Planning

Check condition of wipers and washers

•Check condition of all wiper

blade arms, wiper blade
rubbers, washer hoses
and washer nozzles
Competence Development Planning

Check compressor function and

condition
Competence Development Planning

Check brake pedal and foot brake valve

•Check that the pedal clearance is approx. 5–10 mm.

 Competence Development Planning

Check batteries — dirt, leakage, attachment, fluid

level, connections and battery box

•Make sure the level in the battery cells is about •Check the condition of batteries
18–28 mm above the cell plates (South with battery analyser 9812515 or
America) and 5 -10 mm above the cell plates 9812518.
(Europe).
Competence Development Planning
Check fuel tank, hoses, pipes, venting and
mounting

•Check that the fuel tank venting hose is not blocked.

•Check that the pipes and hoses connected to the combined tank unit are
clamped, do not leak and are not chafed.
•Check that no cracks or leakage occurs in the tank.
•Check that the tank suspension straps are not loose or cracked.
•Check that fuel tank mounting brackets are not loose or cracked.
Competence Development Planning

Check fuel tank ventilation filter

•Check that the filter air inlet is not blocked by dust or dirt.
•Check that the filter and ventilation pipe are intact and
securely fastened.
Competence Development Planning

Check tyre wear

Competence Development Planning

Check of receiver dryer tank, condenser,

pipes and hoses
Competence Development Planning

Check alternator mounting, electrical connections

and cables for alternator, starter motor and
preheating unit
Competence Development Planning

Check drive belts and belt tensioners

Competence Development Planning

Check radiator fan, bearing tolerance, screw

unions, fan shroud and fan ring with rubber
seal
Competence Development Planning

Check engine mounting

•Check that front and rear rubber pads are intact.

•Check that the brackets are in good condition and tightened
Competence Development Planning

Check radiator, hoses, pipes and air

through-flow
Competence Development Planning

Check fuel pipes and lines

•Check that the hose and pipe nipples on the fuel lines do not leak
•Check that the fuel pipes do not leak and are not chafed.
Competence Development Planning

Check for exhaust leakage

 Competence Development Planning

Check intercooler, hoses, pipes and air

through-flow

.
Competence Development Planning

Check air pipe between air intake and turbo

Rubber Valve
Competence Development Planning

Check sealing on servo pump, oil

connections, oil hoses and steering gear
Competence Development Planning

Check Gaiters and Clearance Ball Joints

•If the play exceeds 2 mm, the ball joint

must be changed.
 Competence Development Planning

Check steering link system

! There must be no play evident when checking. No abnormal noise/feel may occur
when the steering wheel is raised or lowered within its range of adjustment.
 Competence Development Planning

Check front shock absorbers

Training Division
TST 1701-1, March 2010
 Competence Development Planning

Check steering knuckle bearing

For FM Axial clearance, steering knuckle - front axle member..... 0.01 - 0.15 mm

•radial clearance, king pin - bushing..... 2 mm

Competence Development Planning

Check front wheel bearings

•If the bearing play is 0.2 mm or greater, the hub and bearing must be
changed immediately to avoid future bearing breakdown.
Competence Development Planning

Check front wheels

Competence Development Planning

Check clutch wear I-Shift

 Competence Development Planning

Check the seal on the speedometer

Check that the seal on the speedometer sensor on the gearbox is intact
Competence Development Planning

Check springs and u-bolts

Check from crack and broken

Competence Development Planning

Check bearing clearance in the pinion and

rear axle input shaft

•The end float on the input shaft for

the final drive must be adjusted if it
exceeds 0.2 mm.
Competence Development Planning

Check sealing of rear axle and hub

reduction
Competence Development Planning

Check propeller shafts – universal joints,

sliding joints and support bearings
 Competence Development Planning

Pastikan posisi marking pada Propeller shaft lurus yang satu

terhadap yang lain.
Grease di dalam spline / sleve hub di ganti tiap 100.000km
 Competence Development Planning

Check brake linings

Minimum permissible brake lining thickness is 5 mm.

 Competence Development Planning

Check brake cylinders, levers and forks

Grease di cek dan di ganti

setiap overhoul brake pad
Competence Development Planning

Check brake lever travel

Competence Development Planning

Check anti-roll bar

•Check the anti–roll bar bushes. Rubber bushes must not have any play and
plastic bushes must not have radial play greater than 2 mm.
Competence Development Planning

Check rear shock absorbers

Competence Development Planning

Check chassis frame and cross members

Competence Development Planning

Change air filter for A/C and check roof-

mounted A/C
Competence Development Planning

Check air intake and air deflector

Competence Development Planning

Check AC—compressor for climate

control system
Competence Development Planning

Check splitter gear control system

Competence Development Planning

Check rear axle ventilation

Competence Development Planning

Pengencangan baut Center

Bogie 850Nm

Setiap Service
 Competence Development Planning

Periksa Spring Belakang dari

kemungkinan retak / patah

Dengan menggunakan Torque wrench

kencankan mur pengikat U- Bolt = 660 Nm
Competence Development Planning

V-stay, axial play, check

Specifications:
1.5 mm
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Welding instruction

 Switch of the main switch

and remove the terminal
battery
Competence Development Planning

Welding instruction

 Remove the ECU

Competence Development Planning

Welding instruction

 Remove MID 144 (VECU) and

if the vehicle have other
control unit should be remove
Competence Development Planning

Welding instruction

 Remove all control unit behind the seat

Competence Development Planning

Welding instruction

 Remove LCM and all

control unit if the
truck have an option
 Competence Development Planning

Welding instruction Version 4

1.

2. Letakkam grown sedekat mungkin dengan media pengelasan.

3. Cabut control unit yang terdekat dengan media pengelasan
 Competence Development Planning

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