2015+ Volvo FH Lorry and Bus Service and Repair Manual

Volvo Trucks. Driving Progress VOLVO FH AND VOLVO FH16 PRODUCT GUIDE VOLVO FH SERIES

2 They say that you shouldn’t change a winning concept. Yet, that’s exactly what we have done. Let us introduce some new features that will add to your driving comfort and safety and make the truck even more useful for many more applications and transport operations. Experience the new dynamic steering, the biggest invention since power steering. Read about the new rear air suspension specifically developed for the quarry and the brand new I-Shift Dual Clutch, taking driving comfort to new heights. Welcome to the future. The truck of the future is now even more futuristic.

4 OVERVIEW VOLVO DIESEL ENGINES Fuel-efficient and torque-strong 13- and 16-litre engines, up to an incredible 750 hp. All fulfilling the Euro 6 standard. Learn more on page 20. INSTRUMENT CLUSTER The modern instrument cluster is designed with the driver in mind, with all information in the right place. Learn more on page 38. DRIVER SUPPORT SYSTEMS The forefront of safety is Volvo’s home ground. Our advanced driver support systems efficiently helps the driver avoid accidents. Learn more on page 42. REAR-VIEW MIRRORS Redesigned aerodynamic mirrors, rear-view cameras and the new upright A-pillars provide visibility you’ve never seen before. Learn more on page 30. HEADLIGHTS Dynamic headlights, static cornering lights, improved main beams and more. Learn more on page 36. VOLVO DYNAMIC STEERING The biggest invention since power steering lets you enjoy effortless manoeuvring with extreme precision. Learn more on page 6. I-SEE A cruise control that plans ahead – our latest addition to the intelligent I-Shift software is revolutionary. Learn more on page 18. VOLVO FH16 The most powerful Volvo ever. And it shows. For the toughest of demands, there really is only one choice. Learn more on page 22. A closer look at the Volvo FH. 42 18 38 30 20 22 36 6

5 VIEW THE COMPLETE SPECS, FROM CHASSIS TO ACCESSORIES, ON PAGES 46–65 I-SHIFT DUAL CLUTCH The new I-Shift Dual Clutch makes the power flow seamless. The benefits are better drivability and unrivalled driver comfort. Learn more on page 10. HANDLING New front springs and steering gear, changes in cab suspension with revised rear anti-roll bar positions all enhance the trucks dynamic performance and driver comfort. Learn more on page 16. REAR AIR SUSPENSION Experience the new air-suspended rear-wheel installation. One could say it’s an earth-moving development. Learn more on page 24. UPTIME The new telematics gateway puts Volvo FH in touch with the workshop from anywhere. Sign up for the new Gold contract to get all the benefits, and an uptime of 100%. Learn more on page 34. THE FUEL DEAL Two packages of real fuel savers for long haul, including products as well as services. Save up to 11% fuel, for the benefit of your bottom line and the environment. Learn more on page 32. CAB INTERIOR The cabs are more spacious than ever and contain lots of innovative features. Learn more on page 12. LOAD HANDLING ECS4 is the latest version of Volvo’s electronical suspension system. The biggest news? A wireless remote. Learn more on page 40. LOW SLEEPER CAB The new extra low cab is ideal for construction or mining operations. Learn more on page 26. I-SHIFT The world’s most intelligent gearbox is now even better. Easy to drive and packed with fuel-saving software. Learn more on page 8. BODYBUILDING INTERFACE The shorter the time at the body- builder, the more time and money there is to save. There are a lot of clever chassis features to help you. Learn more on page 28. 10 16 8 32 40 24 28 12 26 34

6 VOLVO DYNAMIC STEERING Responding to your slightest command. And nothing else. What has been called the biggest thing since power steering is now available in a series-production truck, both with single and dual* front axles. Volvo Dynamic Steering is based on a patented concept, and will completely change the way you drive. Try it, and you’ll never want to go back to a regular truck. Even your car will pale in comparison. * Available during 2015. How it works. Volvo Dynamic Steering consists of an electric motor, connected to the steering gear. By receiving input from several sensors, the Electrical Control Unit (ECU) can determine where the truck is going as well as what the driver’s intentions are. The motor is controlled 2000 times every second, using a principle called ‘torque overlay’, to correct unintentional steering movements and to provide extra torque when needed. Altogether creating a perfect and consistent steering feel, regardless of load or tyres.

7 At low speeds: Steer with one finger and save your back. This is where Volvo Dynamic Steering really will change your day. And your future. Because you no longer need to strain your muscles to manoeuvre the truck at low speeds. Volvo Dynamic Steering provides you with all the steering force you need. You can literally steer the truck with one finger. This not only gives you complete control of the vehicle, but also practically eliminates the strain on your neck and shoulders. When reversing: Perfect control without strain. Reversing with a fully-laden truck is one of the most challenging and trying aspects of the job. Especially when you need to focus every bit of your attention on the surroundings. Not so with Volvo Dynamic Steering. You can now reverse with perfect precision – almost without effort. And as soon as you let go of the wheel, it automatically returns to neutral, reducing the strain even further. Furthermore, if you need to reverse long distances, here’s something new. The course stability is so great that you can reverse a truck and trailer more than a hundred metres without drifting off course. At high speeds: Let nothing set you off course. Driving straight isn’t as easy as one would think. In fact, you often have to compensate for kicks from road ruts, potholes and road markings. Or correct your course after braking on a split-friction surface. Yes, sometimes even side winds can disturb your ride. Volvo Dynamic Steering changes this completely. Just loosen your grip on the wheel, concentrate on the traffic and be sure the truck won’t change direction until you want it to. EFFORTLESS Volvo Dynamic Steering increases the steering force by up to 85%.

I-SHIFT Forget the gearbox. Just drive.

9 How it works. It may seem strange. Beneath the surface of I-Shift, the hallmark of modern transmissions, hides an old-school unsynchronised manual gearbox. (Hence the compact design and low internal losses.) But of course there’s much more to I-Shift than that. The secret lies in the intelligent electronic control unit. It’s responsible for controlling the pneumatic system that handles the clutch and shifts. By constantly receiving information about vehicle speed, acceleration, weight, road grade, torque demand and more, it can carry out every shift with extreme precision. It also communicates closely with the engine, which in turn adjusts revs and engine brake effect for fast and comfortable gear changing. How would you like your I-Shift? The software makes it possible to tailor I-Shift to your driving conditions. Choose from five add-on packages: Long Haul & Fuel Economy (with or without I-See) for efficient highway driving, Distribution & Construction with smart functions for close-quarter manoeuvring and Heavy Duty Transport (with or without I-See) optimising I-Shift for gross combination weights above 85 tonnes. For a complete overview, see page 54. Eases your mind. And lets your left foot rest. Driving I-Shift is a real pleasure. Without the clutch pedal, you can safely sit back and concentrate on the other two. I-Shift uses its built-in intelligence to quickly and automatically choose the right gear at all times. And the software provides shifting skills that are impossible for even the best of drivers to match. Still, if you want to get more involved, you can. The buttons on the shift selector allows you to step in and change gear manually. Volvo FH also offers you the option of either a seat mounted shift selector which allows both automatic and manual changes, or simply four switches on the dashboard for automatic selection only. Freeing that precious space makes it a little easier to move around in the cab. When things get really tough the I-Shift for heavy duty makes it easier. If you’re into really heavy haulage in very hilly terrain you can count yourself lucky as now there’s an I-Shift for you too. Perfectly suited to your specific needs, it offers you all the comfort and fuel economy of the I-Shift gearbox. We’ve developed a clutch with a larger diameter on the damper mechanism and new clutch and gear control software for high torque. The result is an I-Shift gearbox perfectly adapted for timber and construction operations as well as other heavy haulage. Let I-Shift save you fuel. The money will roll right in. I-Shift is designed to save fuel. First of all, the internal energy losses are low – actually lower than on manual gearboxes. But it’s the electronics that really make the difference. When driving in ‘Economy’ mode, every gearchange is timed precisely, to let the engine work at its most efficient rpm range. And then there’s I-Roll. It’s a unique feature used when driving downhill, auto- matically disengaging the engine to make use of the truck’s momentum instead of fuel. The result? Up to 2% lower fuel consumption. Not enough for you? Add I-See to save more. Learn more on page 18. Also available as an accessory. FIND ALL GEAR- BOXES, I-SHIFT AND MANUAL, ON PAGES 54–57

10 I-SHIFT DUAL CLUTCH We drew inspiration from the racing world and created a new gearbox with features that no-one has ever seen in the truck industry – the I-Shift Dual Clutch. With the dual clutch you will experience power shifting with no interruption in torque and power delivery. And still without jeopardising fuel consumption. When your transport operation demands high performance and frequent gear changing, I-Shift Dual Clutch will bring you unrivalled driving comfort. Inspired by motor racing. New, but well proven. Uphill on a slippery road surface? Not a problem. I-Shift Dual Clutch supports you with smooth and fast gear shifting, minimising the risk of getting stuck or losing grip. Yes, I-Shift Dual Clutch is brand new, but it is well tested and proven. Since 2009 we have tested the transmission through millions of kilometres in everyday driving. Thanks to the innovative platform architecture current I-Shift options, like PTO and retarder are possible to install on the I-Shift Dual Clutch. How you will benefit from I-Shift Dual Clutch. Constant power flow, without torque interruption and smooth, dynamic acceleration – these are the main advantages you will experience when driving with I-Shift Dual Clutch. It’s called power shifting and that’s why your ride will be even more comfortable and relaxed. You will also notice the swift acceleration, making it easier to follow the traffic pace. I-Shift Dual Clutch is the perfect choice for demanding operations. I-Shift Dual Clutch is available together with D13K engines with power levels 460, 500 and 540 hp. Explore the technical data and the software packages of the I-Shift Dual Clutch transmission on page 55. How it works. The two dry clutches are located at the front of the gearbox. In normal operation, one clutch is idling while the other is engaged. The clutches and gear shifting are controlled by a pneumatic system, similar to the well-known I-Shift. Basically, the dual-clutch transmission can pre-select the next gear while driving in the current gear. When the gear is changed, the currently engaged clutch is released at the same time as the previously idling clutch is being engaged. This means that the gear shifting is made with no interruption in power delivery. With two input shafts and the gearwheels and selecting elements ingeniously arranged, two gears can be selected at the same time.