Foundation Training

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
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
1
Function Group
233
Model
FH12
2
3
Information Type All Service Information
All
0 General
> 20 General
> 21 Engine
> 23 Fuel system
>> 230 General
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
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.
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
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
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
Function Group
233
Model
FH12
Information Type Parts
All
0 General
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
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
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
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
Function Group
233
Model
FH12
Information Type All Service Information
All
0 General
> 20 General
> 21 Engine
> 23 Fuel system
>> 230 General
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.
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

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
46

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
48

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
50

Personal
Protection - cont.
ear defenders - when using, or working near, any noisy

equipment e.g. when grinding/cutting/drilling.
51
12 volt
+ 24 volt
+
_
+
12 volt
_
Negative earth
Two batteries connected in series

52

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
54

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

Lubricants and
fluids
56

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

Lubricants and
fluids
58

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

Lifting equipment
60

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
62

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
64

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
66

! 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.
68

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
70

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

73
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

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

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

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

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
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 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
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

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
84

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
86

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

4 Measuring
- tyres
37. Tyre Depth (7/8)
O/S
N/S
37. Tyre Pressure

(7/8)
O/S
N/S
88

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

4 Measuring
- brakes
78. Brake test overall result (71, 72, 73)
Service (71)
Sec (72)
Park (73)
50%
Service Brake footbrake

90

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

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

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

4 Measuring
- brakes
Service (71)
Sec (72)
Park (73)
25%
Secondary
Brake
94

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

4 Measuring
- brakes
Service (71)
Sec (72)
Park (73)
16%
Park Brake
96

4 Measuring
- brakes
Park brake
test
Minimum acceptable values are:

- 16% of GVW
- 12% Gross Train Weight (GTW) if type approval
certificate.
97

1
(9988698)
<
X2
>
X1
X2
98

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

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

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

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

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

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

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.
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

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
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
Start
110

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

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

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

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What are the main components of Volvo's brand image?

What are the main components of Volvo's brand image?

What headings are used to indicate risk of injury or damage?

What headings are used to indicate risk of injury or damage?

TRAINING TIPS &

This guide is intended as a memory jogger for the

This guide is not intended as a substitute for the Service

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

Read and implement all DANGER, WARNING and

When replacement parts are required, it is essential that

Volvo are constantly seeking ways to improve their

All rights reserved. No part of this publication may be

Volvo Truck & Bus Ltd 2004

Brand image is an extremely important and valuable asset

Quality & Safety

The Volvo brand image is firmly established and

You can make your contribution in many ways; here are

Quality work is a fundamental part of all activities,

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

Safety applies to:

Volvos concern for our environment takes in the whole

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

open a new job card

open an existing job card

The main icons

Note: Icons become active/inactive dependent on which

- Citrix ICA client, & Uniprint must be installed.

- enter Impact web-site address:

Displays last 20 places visited

Displays latest updates remains for 6 weeks

By making the right selections you can search for either

You can search with or without a chassis number.

Information Type Parts

Fuel filter, engine

Information Type All Service Information

All Service Information

23303-2 Fuel filter, replace (one)

Reception Vehicle Service and Parts

1 Open a new job card.

Information Type Parts

FH12 , 23, Parts< FH12 CHID

10 Press Show button - a new window now appears.

Reception Vehicle Service and Parts

1 Open a new job card.

Information Type All Service Information

All Service Information

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

Safe Working Practices

Safe working practices

Safe working is largely down to you.

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

Safe working practices

Safe working practices

You have a legal responsibility to ensure that:

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

The right gear

Health & safety

you use the Volvo, or dealer, specified safety clothing

Safe working practices

Safe working practices