KEY FACTS
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MAKE: Volvo.
MODEL: FH12 420.
CONFIGURATION: 4x2 tractive unit.
SERVICE INTERVALS: Intermediate, six weeks; basic 45,000km. SERVICE LEVELS: Intermediate, basic and annual.
SERVICE SEQUENCE: Alternating intermediate and basic with annual every year/fourth basic service.
STANDARD TIMES: Intermediate 2hr; basic 3hr; annual 5.5hr. ENGINE: Description; Dl 2A 12-litre in-line six-cylinder intercooled. Tappet clearance (cold): set when necessary. With VEB: Inlet, 0.2mm; exhaust, 1.6mm; injector, 0.75mm pre load. Without VEB: Inlet, 0.2mm; exhaust, 0.5mm; injector, 0.75mm pre load. Oil: Quantity, 36 litres (39 for off-road vehicles). Specification and drain period: 15W/40 to VDS 1 or API CF4 drain at 45,000km.
OIL FILTRATION: Two full flow filters plus a single bypass filter; change period—with oil change on both basic and annual services. Filter fitting procedure; lubricate the seals and hand tighten. Cost of full flow filter (x2) £10.50 (ex-VAT) each, bypass filter, £16.88 (ex-VAT).
COOLANT: Header tank located behind hinged front grille. Change period, four years; quantity, 44 litres. Antifreeze (including inhibitor) concentration, 50%.
WATER FILTER Change period, six months (but not when coolant is changed). Cost of filter, £24.99 ex-VAT.
FUEL SYSTEM: Single disposable element filter. Change period, at every basic and annual service. Fitting procedure: lubricate seal and hand tighten. Cost of filter £5.99 (ex-VAT).
CLUTCH: Single plate with air assistance.
Adjustment: automatic; initial setting, 55mm. Fluid: top up only with SAE J1703 or DOT 3.
GEARBOX: Volvo SR1900.
Oil change period, annual service; capacity of SR 1900 gearbox, 13.5 litres of 80W to API GL4 (options of SR 1700 on lower powered models also take 13.5 litres; the non-splitter R1700 takes 12 litres.) Additional items: change oil filter on annual service. Fitting procedure: lubricate oil seal and hand tighten. Cost of filter: £4.64 (ex-VAT).
REAR AXLE: Volvo RA EV 90. Oil change period, annual service for every third basic service if covering more than 120,000km/yr); capacity, 11 litres; specification, SAE90 to API GL5. SAE80W/90 must not be used.
FRONT AXLE: Volvo FAL 7,1. Kingpin check: using set square to measure movement of wheel with hand brake on (maximum permitted movement 5.25mm with 22.5in wheels). Check oil level in front hubs on basic and annual service. Top up with SAE 30 (do not use multigrade). End float on wheel bearing from 0.1mm to a pre-load equivalent to 4kg force to keep hub rotating.
BRAKES: Air operated Z-cam drums. Minimum air pressure 7.8bar. Twin element desiccant filter change, every two years (every year for single element). Minimum lining thickness, 5mm. Adjustment: automatic integral adjustment. Maximum stroke, see type/lever length chart.
POWER STEERING FLUID: Check/top-up every basic/annual service; filter change period, annual service (fluid is not changed). Top-up with ATF fluid. Cost of filter: £6.47 (ex-VAT). AIR FILTER: Change period (unless restriction indicator shows a blockage), two years with rear mounted intake; one year with intake behind front grille. Cost of filter, £54 (ex-VAT). GREASE: Lithium based to NLGI 2 with EP additive. Grease points: cab pivots, steering column UJ, gear lever carrier, front and rear brake cross-shafts, king pins (two at top one at bottom), front road springs (two at rear, one at front) and propshaft UJs.
TIGHTENING TORQUES: Wheel nuts (right/h), 625Nm±75Nm.
While Volvo's latest FH cab looks different, from the workshop point of view it's the changes beneath it that are of greater interest. The 12-litre engine now comes equipped with electronically controlled unit injectors driven by an overhead camshaft. This also operates four valves per cylinder and can incorporate Volvo's engine brake (VEB).
To find out the servicing requirements of the FH12 we visited the font of all knowledge on things Volvo, its training centre at Warwick. Instructor Julian Jones pointed out where difficulties can arise in servicing the FH12 using a new vehicle and a stand mounted engine in one of the workshops.
We took a look at the most powerful 12 litre version, a 420hp 4x2 tractive unit equipped with Volvo's engine braking system and an air-suspended rear axle. With the electronic engine comes a diagnostic button with flash codes (hidden in the centre console) and a computer links capability for the engine and ABS systems.
Workshop manuals containing all procedures, torques and fault codes for Volvo vehicles are available from the dealers. Fleet fitters can also attend courses at Warwick.