DESCRIPTION

GENERAL INFORMATION

IMPORTANT – Use these instructions along with the applicable vehicle specific Pre-Delivery Inspection Report Form when inspecting a vehicle.

These instructions explain how to inspect the vehicle and use the Pre-Delivery Inspection Report Form to be sure the vehicle is ready for delivery to the customer. Each inspection operation on the report has a corresponding procedure on the following pages in this Pre-Delivery Inspection Master Instruction Manual.

The original Pre-Delivery Inspection Report Form should be retained at the TICO EDGE Case Management system.

NOTE – Fill in the information block on the report after the vehicle is driven into the inspection area.

The instructions described in this manual follow the order of operations listed in the Pre-Delivery Inspection Report. If a question arises while performing an inspection, use the Pre-Delivery Inspection Report Form Task Reference number as a reference to find the corresponding procedure instructions and specifications in this manual required to properly complete the inspection line item.

EXAMPLE: For a question about engine oil level, refer to the Task Reference number on the form: number

11.50. Then refer to Task Reference number 11.50 in this manual for details on how to correctly complete the task. Applicable NOTES, specifications, and warranty information are also included.

PTD Warranty “Pre-Truck Delivery” is a separate warranty case for items discovered during the Pre-Delivery Inspection. The PDI case should be referenced in the separate PTD Warranty case in EDGE.

Non–Reimbursement Statement

Labor time and or materials for procedures in addition to inspections which are included as a part of the PDI

include but are not necessarily limited to the following:

1. PDI Preparation

   • Labor to retrieve and return vehicle at PDI location and prepare inspection service bay, supplies, and tools for PDI

2. Clerical Work

   • Labor and office materials to acquire and complete forms, instructions, labels, and vehicle history.

   • Labor to complete and affix labels and file paperwork.

3. Vehicle Completion

   • Labor and materials to install parts and/or materials shipped with or for vehicle that were not installed/ properly installed due to complications associated with vehicle delivery practices, etc.

4. Reversal of Vehicle Driveaway Company effects

   • Labor and materials associated with retorquing fasteners, installing temporarily removed components, replacing rearmost axle flange gaskets

5. General Procedures

   • Labor and material expenses associated with battery charging, and general non-inspection steps, etc., necessary to complete the PDI.

6. Adjustments

   • Labor associated with adjusting fluid levels, tire pressures, and steering wheel alignment. See Instructions for the specific task

7. Retorques

   • Labor associated with retorquing items such as spring U-bolts, wheels, axle flanges, hose clamps, etc.

8. Programming

   • Labor associated with initial programming/ reprogramming standard and optional equipment such as engines, transmissions, various ECU’s.

9. Tie Wrapping and Routing and Clipping Adjustments

   • Labor and materials associated with adjusting routing and clipping and tie wraps or added clipping materials.

10. Reconnecting loose Electrical Connectors

    • Labor associated with re-connecting electrical connectors that were inadvertently left disconnected or may have come apart during shipment.

11. Lubrication

    • Labor and materials (grease, etc.) associated with lubricating various vehicle chassis and body components.

12. Road Test

    • Labor associated with conducting a vehicle road test as specified in the road test instructions in this manual.

13. Vehicle Cleaning and Protective Coatings Removal

    • Labor and materials (water, soaps, solvents, polishes, etc.) associated with the effective removal of protective coatings and their adhesives, and shipping blocks, as well as washing and cleaning the entire vehicle inside and out as needed for full customer satisfaction.

14. Consumables such as windshield washer solvent, diesel fuel, coolant additives, etc. and inspections of those items are not included in the PDI, but will allowable as a PTD case tied to the PDI inspection. See Note O for billable quanity

15. Added engine oil (qts.), transmission fluid (pts.), drive axle oil (pts.), wheel hub oil (oz.) - materials only - will be reimbursed as PTD case warranty expense. Only the cost of the quantity of fluid used should be charged or closest gallon container.

16. Damage due to shipping should be claimed with the shipping carrier. All other repair operations should be charged to the appropriate OEM or supplier warranty.

TICO. reserves the right to change these specifications and content at any time.

Table 1 Suggested PDI Tools

GENERAL INSTRUCTIONS

Listed at the top of the Pre-Delivery Inspection Report Form is the title and the revision date of the form being viewed. Be sure that the title matches the model of vehicle on which a PDI is to be performed. If the form was not directly printed from TICO EDGE Knowledge on the day of the inspection, check on TICO EDGE Knowledge to verify the latest revision of the form is being used. Print out an updated form if necessary and destroy all previously printed out-of-date Pre-Delivery Inspection Report Forms and Pre-Delivery Inspection Instruction Manuals.

Boxes are provided at the top of the Pre-Delivery Inspection Report Form to link the form with the vehicle and provide specific details for future reference and documentation. The various boxes to be completed on the Pre-Delivery Inspection Report Form include:

• Vehicle Model

• Vehicle Gold Sticker Date

• PDI Facility Name and Location

• The last 8 digits of the VIN

• The Mileage on the Vehicle at the time of PDI

• R.O. No. (Dealer’s related Repair Order Number) (if applicable)

• Customer (End user) Name and Location

• The Hour meter on the Vehicle at time of PDI

• Engine Serial Number

• Transmission Serial Number

• 5^th wheel Serial Number

• Differential Serial Number

Inspection Line items and procedures

Read the Line Item. Perform the inspection/ task as instructed in this Manual. If the Line Item has been successfully completed or the inspected components are in an acceptable condition/working order, select SATISFACTORY in the corresponding box in the OUTCOME column. If the line item CANNOT be

successfully completed or the inspected components are in an unacceptable condition/working order, select REQUIRED ADJUSTMENT or REQUIRED REPAIR in the corresponding box in the OUTCOME column. Also describe what the problem is in writing in the Notes section under the Outcome box. After the item has been adjusted/repaired by the PDI Inspector (in the case of a fluid level adjustment, for example) or a technician (in the event of a PTD warranty repair), the item may be reinspected and the corresponding box in the ACCEPT AS RECEIVED column may be marked.

INSPECTION INSTRUCTIONS

1.10 Research VIN for Recalls / Updates

1. Indicate on Pre-Delivery Inspection Report the vehicle Model, PDI Facility Name and Location, VIN, R.O. No. (if applicable),

2. On the same page check Calibration Status link for required engine updates and ESC updates.

3. Document updates, any open Recalls, open AFC’s, or UpTime issues in COMMENTS section of PDI Report Form.

4. Volvo EV Drivelines, review product center for open campaigns against EDL Serial Number. Volvo Penta Product Center

1.20 Prepare Vehicle for PDI - Wheel Chocks

WARNING – To avoid property damage, personal injury or death, park the vehicle on a flat level surface, set the parking brake, chock the wheels and turn the engine off.

NOTE – PDI should take place in a well-lit location with a smooth level ground (a slight grade for water drainage is acceptable) to assure accurate fluid level checks.

1. Assure vehicle has 115+ psi air pressure in the brake system per dash gauges.

2. Turn OFF key.

3. Install wheel chocks to prevent vehicle movement forward or backward.

4. On air brake vehicles, release parking brake to pressurize parking brake release circuit to assist in leak detection.

5. Cover seats (if uncovered) and floor mat with protective coverings to protect them from dirt during PDI.

3.30 Charge Battery - Auto Max. Charge - 1.3 hr minimum*

* Unless Midtronics 55 amp Smart Charger is used and light on charger goes to continuous (not flashing) green in less than 2 hours. It is still recommended to keep the battery charger connected both before and after the Road Test due to the high likelihood of current draw with engine OFF during the inspection.

FOR 12V PARALLEL SYSTEMS

1. Carefully connect smart battery charger and charge batteries for a minimum of 2 hours.*

2. Turn charger ON at 12V automatic high rate of charge. Watch for Incorrect Hook-Up warning.

3. Continue to charge the batteries until the green LED illuminates continuously. Continue charging after Road Test if necessary.

NOTE – If batteries are cool [less than 60 deg F (16 deg C)], moving vehicle into a heated facility will shorten charging time required. It may take up to 20 hours to achieve a full charge if the batteries are charged in a very cold [0 deg F (-17 deg C)] environment.

3.40 Batteries, Cables, Cover - routing, tight, greased

1. Battery cable end connections in box should be tight and secure.

2. Battery cable end connections should be protected by dielectric grease.

3. Cables are not kinked, crimped, pinched or rubbing when box moves.

4. Batteries are securely fastened in box.

5. Document items to be repaired on PDI Report.

3.50 Install loose components shipped for or with the vehicle

1. These include:

   1. Tailpipes/ Vertical exhaust stacks should be fully inserted into exhaust pipe

      • Exhaust stacks should be properly aligned if applicable

      • Clamps should be tight and secure, and installed in overlapping area between upper and lower stacks

        1. Torque Specifications:

           • Aluminized band, bright hardware - 44 to 59 ft-lbs.

           • 409 Stainless band, dull gray hardware - 35 to 46 ft-lbs.

           • If in doubt, torque to 46 ft-lbs.

        2. Correct as needed.

   2. Trailer connections

   3. Light cords

   4. Mud flaps

   5. Strobe lights

   6. Any other mounted/installed component shipped with the vehicle and not installed by the plant.

2. Document items to be repaired/ missing parts on PDI Report.

3.60 Mud flaps / Fenders - secure, aligned, clears exhaust

1. Mud flaps should be securely mounted.

2. Fenders should be properly aligned with the vehicle body.

3. Mud flaps should not hit tires.

4. Document items to be repaired on PDI Report.

NOTE – Labor for the installation and inspection of dealer supplied mudflaps is not covered under PDI.

5.10 Routing and clipping under vehicle - secured, meets specs

1. Check the following items:

   1. Electrical wiring harnesses

   2. Battery cables

   3. Air hoses

   4. Fuel hoses

   5. Coolant/heater hoses

   6. Power steering hoses

   7. Transmission cooler / retarder lines

   8. Refrigerant hoses

   9. Added hydraulic equipment / hosing.

2. All cables, hoses, and wires should be:

   1. Well supported — not sagging or hanging loose where they can get into objects and rub

   2. Free from tension

   3. Has adequate clearance from heat source

   4. Clear from any rub or pinch point

   5. Free from kinking or pinching

   6. Should NOT block access to any fluid fill, fluid drain, or inspection points

   7. Compressor discharge line should be free from any low points, or "water traps"

3. Listen for audible air leaks (and optionally the Ultrasonic Leak Detector if desired). Spray a liquid soap solution on any suspect air connections. Bubbles indicate a leak.

4. Correct minor routing and clipping problems using tie wraps as needed during PDI.

NOTE: Cost of tie wraps and labor is included in PDI. Do not file for additional PTD Warranty.

1. Document items to be corrected on PDI Report.

5.15 Drive Wheel Hub Gear Cases Oil Level — FULL

1. Oil level on oil-filled rear drive gear case hubs should be at or above the "OIL LEVEL" / "MINIMUM LEVEL" line on the view window and be below the vent plug opening. Oil should not pour out if the rubber cap is removed.

2. Add or remove oil as needed during PDI to bring level to the proper range on the hub.

3. Verify that drain plug is snug and leak-free.

4. Make sure vent is attached

5. If equipped with Diff lock, make sure lock pin in removed and secured per Meritor standards

NOTE: If fluid level is within specified operating range, further fluid additions are not necessary and are not covered by PTD Warranty. Only fluid added, not labor, is covered by PTD Warranty.

5.20 Rearmost Drive Shaft U-joints - in-phase, retorque*

1. Verify that the rearmost 2 driveshaft joints are in alignment with each other.

2. If required, realign driveshaft U-Joints as part of PDI.

NOTE: Retorque as specified using new bolts and collars.

NOTE: The chances of driveshaft phase angle misalignment is greater on vehicles that have had their driveshaft disconnected during new vehicle delivery.

5.30 Shock Absorbers / Bump Stops - secure

1. Verify that shock absorbers are securely installed

2. Verify that bump stops are securely installed.

3. Document items to be repaired on PDI Report.

5.35 Slack Adjusters - (Stroke <1.75" STD, <2.0" LS) *

* Specs listed in the Task title are the most conservative and will work for all brake chambers. They are listed as a quick reference for convenience. Maximum acceptable legal chamber stroke specifications may be longer for larger brake chambers. Refer to the chart below.

Table 2 Maximum Legal Brake Slack Adjuster/ Chamber Stroke

1. Inspect the Brake Slack Adjuster/ Chamber Stroke at 90 to 100 PSI application pressure (not more or less) to assure it is less than the specifications shown in the chart above.

2. If stroke exceeds the specification listed or over-stroke indicator is visible, brake chambers are over-stroking and slack adjusters must be adjusted.

3. Document items to be adjusted on PDI Report.

5.40 Electrical System

1. Check battery terminals for loose connections and cable routing, to batteries, Cab PDC and Chassis PDC.

2. Confirm constant battery power to 6S terminals on Cab relay panels

3. Confirm ignitions power to 5S terminals on Cab relay panel

4. Check back up alarm operation

5. Check gauges functioning

6. Check switches are operational while engine is running

5.41 Air conditioning and heating

1. Check routing of A / C lines (if applicable): check for kinked lines. All lines should be tied down or clamped

2. Record Max A/C / Heat temperatures _ F Temp should be between 49 and 52 degrees at normal operating condition.

3. Check heater operation: check heat coming out of vents and air flow.

4. Test HVAC function making sure AC compressor is cycling.  Blend door is switching from Hot to cold.  

5.45 Exhaust - secure, position, tailpipe end location

1. The exhaust system should be securely mounted to the frame/ Cab bar.

2. Exhaust system joints should be tight and leak free. Look for evidence of leakage such as soot or slobber around the joints.

3. Exhaust system sensors, cables, tubes, and hoses should be tension free and should not rub any object.

4. Exhaust tailpipe must terminate at DOT or State specified location or range.

5. Exhaust tailpipe must not contact mud flaps or other non-exhaust components.

6. Document items to be repaired on PDI Report.

5.50 Air Tank Drain Valves - activate

1. All air tank drain valves must function properly.

2. Document items to be repaired on PDI Report.

5.60 Transfer Case Oil Level - FULL — torque both plugs

1. Verify that oil level is filled level with fill port. Add fluid as needed.

2. Verify that the fill plug and the drain plug are torqued to spec. and leak-free.

5.65 Transmission Oil Level - FULL — torque both plugs

1. Verify that oil level is filled level with bottom of the fill plug opening. Add fluid as needed.

2. NOTE: Be sure to top off with the correct fluid type (Allison Approved TES 295 Automatic Transmission Fluid) Allow an overfilled transmission to drain excess fluid.

3. Verify that the fill plug and the drain plug are torqued to spec. and leak-free.

4. Check breather is installed, open and free of obstructions

NOTE: Labor is covered within PDI. Fluid added is covered under PTD Warranty.

5.85 Starter, Ground Connections - tight, greased

1. Inspect cable end tightness. Connections should be tight and coated with dielectric grease.

2. Cable ends make no contact with other vehicle hardware.

3. Document items to be repaired on PDI Report.

5.90 Lubricate chassis - zerks,

1. Lubricate all grease zerks including:

   • King Pins (4 zerks) and King Pin Thrust Bearings (2) with vehicle weight on tires

   • Tie Rod Ends (2)

   • Drag Link Ends (2)

   • Steering Intermediate Shaft (2) U-Joints and (1) Slip Joint

   • Boom pivots (2)

   • Brake Cam Shafts (6) on 6x4, (4) on 4x2

   • Brake Slack Adjusters (6) on 6x4, (4) on 4x2

   • Drive Shaft U-Joints

   • Drive Shaft Slip Joints (2) on 6x4, (1) on 4x2 (10-Series Drive Shafts Only!)

   • 5th Wheel Pivot Pins (0 to 4)

   • 5th Wheel Slider Mechanism (0 to 4)

   • 5th Wheel Top Plate and Locking Jaw (additional details covered in separate 5th Wheel line item)

LUBRICATION CHART

See Figures 2-1 and 2-2.

NOTE: Labor and cost of Lubricant materials to lubricate chassis are included within PDI. It is not included in PTD Warranty.

5.95 Steer Axle Spring U-bolts - retorque (See Torque Chart)

1. See TES-106 Torque

2. Check kingpins, bushings, bearings for ease of movement.

3. Check steer response: confirm that axle stops are properly aligned with gear box stops.

4. Check gear box mounting: Torque to 460 ft lbs.

5. Check power steering fluid level.

6. Check steer axle bolts are torqued to 210ft lbs.

7.15 Fifth Wheel - lubed, functions, secured

NOTE: Labor and cost of Lubricant materials to lubricate chassis/ 5th wheel are included within PDI. It is not included in PTD Warranty.

1. Refer to the Holland operator’s manual for proper lubrication procedures.

2. Fifth wheel should lock / unlock smoothly and fully.

NOTE: Activate Jaw Release

1. Document major component issues to be repaired on PDI Report.

7.20 Pintle Hook - locks, releases, secure

1. Pintle hook and mounting hardware should be tight and secure.

2. Pintle hook should release and open easily.

3. Pintle hook should lock securely.

4. Attempt to correct with lubrication during PDI.

5. Document items to be repaired on PDI Report.

7.30 Drive Axle mounting bolts - retorque (see TES-106 Torque)

1. Check drive axle bolts: Torque evenly spaced front and back of axle to 600 ft. Lbs. at head. Nut to 480ft lbs.

2. Check breather: should not be damaged, missing, or plugged.

7.35 Drive Axle Oil Level FULL (all drive axles)

1. Verify vehicle is on level ground. If not, move the vehicle to level ground.

2. Verify that the oil level in all Drive Axle(s) is at the bottom of the fill plug opening.

3. Allow an overfilled Drive Axle to drain excess fluid.

4. Add fluid as needed.

NOTE: Be sure to top off with the correct fluid type. Verify that the fill plug and the drain plug are torqued to spec. and leak-free.

NOTE – Labor is covered within PDI. Fluid added is covered under PTD Warranty.

7.45 All Wheel Lug Nuts - retorque to 450 — 500 lb.-ft

1. Check torque on all wheel mounting nuts

2. The torque should be 450 — 500 lb.-ft (610 — 678 Nm).

7.55 Tires - proper inflation, valve stem caps are tight

NOTE – Tires may come from the vendor inflated below the maximum pressure indicated on the sidewall.

1. Tire pressure should be checked with a pressure gauge that is calibrated at least 4 times per year.

— An air tire valve chuck with an integral dial pressure gage will speed up this process.

1. Steer tires should be inflated to 110 PSI 724 kPa Rear tires should be inflated to 110 PSI 655 kPa. Other tire options may require different pressure specifications. See the tire manufacturer’s literature for additional information.

2. Front tires should be inflated to the "MAX LOAD SINGLE" tire pressure listed on the sidewall + 5 / -5 PSI.

3. Correct tire pressure as needed during PDI

4. Re-install valve stem caps tightly.

5. If one or more tires of a like kind is more than 15 PSI lower in pressure than the other tires of like kind, document tire(s) to be inspected for slow leaks on PDI Report.

7.60 Front Hub Oil Level - in range

1. The oil level on oil filled front hubs should be between indicators.

2. Add or remove appropriate oil as needed to bring level to the indicator circle on the hub.

NOTE – If fluid level is in acceptable operating range, further fluid additions are not covered by PTD Warranty. Only fluid added, not labor, is covered by PTD Warranty.

7.65 Cab Tilt / Assist / Latch / Lockout Mechanisms

1. Cab should tilt smoothly, easily, quietly.

2. Cab tilt lock-out should work properly

3. First latch works properly - catch and release.

4. Secondary latch works properly - catch and release.

5. Mechanism latches cab firmly.

6. Cab lock bar should fall into place without assistance.

7. Confirm that cab pivot blocks assembly bolts, studs and nut are torqued to TES specifications

8. Document items to be repaired on PDI Report

7.75 Cab Skirts - secure, alignment

1. Cab extenders and Chassis Skirts should be properly aligned and securely mounted.

2. Document items to be repaired on PDI Report.

7.80 Cab Ride Height - re-attach linkage

NOTE – The cab air bag(s) may not inflate if there is not at least 110 PSI air pressure on both air pressure gages on the dashboard.

NOTE: It should not be necessary to adjust the height after the linkage is connected. The height valve linkage should not be disassembled, or the locknut (if applicable) loosened.

NOTE: Measuring or resetting the cab height is not covered under PDI.

1. Document items to be repaired/ missing parts on PDI Report.

9.20 Remove Protective Coverings, Tags, Tape

1. Remove protective coatings from entire vehicle except for plastic seat covers.

2. Remove any adhesives left behind after protective coatings are removed.

3. Document items to be repaired on PDI Report.

   1. External Paint, Exterior components - condition, fit

4. Remove any protective coatings added for shipping.

5. External painted/unpainted and plated surfaces should be free from runs, scratches, scuffs, dents, bumps, holes, or other obvious defects.

6. Cab and trim pieces should be securely affixed and aligned, and in good condition.

7. Mirrors, Bumper and Chassis Skirts should be securely mounted and in good condition.

8. Document items to be corrected and any other body damage on PDI Report.

9.40 Windshield and glass - no damage

1. Windshield and other glass should be free from cracks, stars, chips, or other obvious defects.

2. Use straight edge to confirm no bowing in the front fiberglass below windshield

3. Document items to be corrected on PDI Report.

11.10 Steering Shaft Pinch Bolts - both torqued off

1. Pinch bolts should be twisted off at each end of steering intermediate shaft.

2. Feel or look to see that the top surface of the head of the pinch bolt is relatively smooth and that the 5/16" (8mm) hex head has been removed during the torquing process. A round raw steel fractured circle can be seen where the hex head fractured off.

3. Re-torque if required (included in PDI labor).

4. Document items to be repaired on PDI Report.

11.15 Air Filter Cobra Boot — fully attached

NOTE – The engine air filter Cobra Boot may have been pulled loose because it was used inappropriately as a grab handle.

1. Carefully verify Cobra Boot is fully connected to the air filter housing as designed. Must prevent dust / water/ under cab air entry at joint.

2. Re-attach Snorkel Boot if necessary, during PDI.

3. Ensure all intake boots are fully secured and not rolled over causing unfiltered air to access intake system.

4. The air filter should be securely installed.

5. Ensure the air filter cover is tight and the evacuation valve is positioned vertically "down" position to ensure proper water drainage.

6. Document items to be repaired on PDI Report.

11.20 Turbo downpipe - secure, no contact with hardware

1. Verify Turbo to Downpipe connection is secure and well positioned.

2. Downpipe makes no contact with other vehicle hardware.

3. Confirm flex pipe is secured to frame

4. Confirm cab is not resting on exhaust elbow

5. Document items to be repaired on PDI Report.

11.25 Alternator Connections - tight, greased

1. Inspect cable end tightness. Connections should be tight and coated with dielectric grease.

2. Cable ends make no contact with other vehicle hardware.

3. Document items to be repaired on PDI Report.

11.20 Engine mounts.

1. Check for loose bolts on engine mounts on both rear and front crossmember.

11.30 Engine Compartment route and clip - secure, meets specs

1. Check the following items:

   1. Electrical wiring harnesses

   2. Battery cables

   3. Air hoses

   4. Fuel hoses

   5. Coolant/heater hoses

   6. Power steering hoses

   7. Transmission cooler

   8. Refrigerant hoses

   9. hydraulic hoses

2. All cables, hoses, and wires should:

   1. Be well supported — not sagging or hanging loose where they can get into objects and rub

   2. Be free from tension

   3. Have adequate clearance from heat source

   4. Be clear from any rub or pinch point

   5. Be free from kinking or pinching

   6. NOT block access to any fluid fill, fluid drain, or inspection points

   7. Compressor discharge line should be free from any low points, or "water traps"

3. Listen for audible air leaks (and optionally the Ultrasonic Leak Detector if desired). Spray a liquid soap solution on any suspect air connections. Bubbles indicate a leak.

4. Correct minor routing and clipping problems using tie wraps as needed during PDI.

NOTE: Cost of tie wraps and labor is included in PDI. Do not file for additional PTD Warranty.

1. Document items to be corrected on PDI Report.

11.35 Engine Compartment wire connections - latched / tight

1. Verify all wire harness electrical connections are securely latched.

2. Re-latch as needed during PDI.

3. Document items to be corrected on PDI Report.

11.40 Engine Compartment hose clamps - tight, position

1. Verify clamp orientation allows good access.

2. For hose clamps:

   1. Aluminum pipe, re-tighten to 50 - 60 in-lbs.

   2. Steel pipe, re-tighten to 70 - 75 in-lbs.

11.45 Engine accessory drive belt(s) - proper alignment

1. Engine accessory drive belt(s) should be properly seated on all pulleys.

2. Engine accessory drive belt automatic tensioner(s) should maintain appropriate tension on belt(s).

3. Correct as needed.

11.50 Engine Oil Level - in upper half of range

NOTE: Engine should be turned OFF for at least 5 minutes before checking level to allow oil to drain to oil pan.

1. Engine oil level in upper half of ADD-FULL range on dipstick is considered acceptable as-is.

2. Add or drain oil as needed during PDI to put fluid level in acceptable range.

NOTE: If fluid level is in acceptable operating range, further fluid additions are not covered by PTD Warranty. Only fluid added, not labor, is covered by PTD Warranty.

11.55 Washer Fluid Level if equipped— over half full

A. Washer fluid level should be half-full or higher. Add fluid as required.

NOTE: Washer fluid added is at dealer labor and material expense to be charged toward purchase cost of vehicle. Do not charge to PTD Warranty.

11.60 Open All Coolant/ Heater Valves

A. Open all coolant valves on vehicle prior to Road Test so that coolant circulates through all circuits.

NOTE: Some installations have two hand valves in the engine compartment.

11.70 Air Restriction indicator

1. Check the operation of the reset button on air minder. Indicator is located on the intake tube on the engine.

2. Document items to be repaired on PDI Report.

3. Document items to be repaired/ missing parts on PDI Report

11.80 Fire Extinguisher/ Reflector Kit - fit, secured, full

1. If specified, the Fire Extinguisher is installed squarely and tightly in the designed location and the latch stays latched.

2. If specified, the Warning Reflector Flare Kit is installed squarely in the designed location and the kit is secure.

3. Assure Fire Extinguisher is full (per gage on unit) and Reflector Kit contains 3 triangles.

4. If specified, Tool Kit is installed squarely and tightly in the designed location.

5. Document items to be repaired on PDI Report.

11.90 Door - adjusted and work properly

Includes:

1. Entry Doors

2. Latches

3. Lock

4. Hinges

5. Door seal

6. Air over Electrical Actuators

7. Air pressure set between 40-60 psi at gauge under cab

8. Adjust so doors to not bind or slam during open or closing procedure

9. Emergency shut off releases air pressure from door operation.

• Document items to be repaired on PDI Report.

12.00 Lights - exterior, instrument panel, interior,

1. Install Strobe light on cab bar if equipped.

2. Check interior lights, dome lights, and all exterior lights including steering wheel-mounted switches such as Flashers, stops parking, and reverse lamps.

3. Check dash lights dim and brighten with switch

4. Check headlight operation

NOTE: Use of mirrors in inspection bay is recommended.

• Document items to be repaired on PDI Report.

13.19 Windshield Wiper / Washer, Windshield — functional if equipped

1. Verify windshield wipers work in all positions (HI/LO/Intermittent/OFF) and do not contact each other or window frames. NOTE: If the windshield is exceptionally dirty, wipe off the windshield with clean cloth prior to wiper test to avoid scratching the windshield.

NOTE: Windshield washer fluid addition and level inspection are not covered by PDI.

1. All washer fluid nozzles spray in an acceptable pattern.

2. The windshield is clean and free of cracks/ damage.

3. Document items to be repaired on PDI Report.

13.22 Radio /VID / Speakers - fit, function (as equipped)

1. Radio(optional) - Controls: Volume, AM FM, Station Change, and Speakers function properly.

2. Optional Vehicle Information Display (VID) turns on and buttons work.

3. Exposed Speakers fit squarely and tightly.

4. Document items to be repaired on PDI Report.

13.24 Mirrors - condition, mounting, adjustment

1. Verify proper function, mounting integrity, condition, and adjustability of all manual and or motorized mirrors both inside and outside vehicle.

2. Check operation of heated function if equipped.

3. Document items to be repaired on PDI Report.

13.25 Steering Wheel, Dif-lock, PDL, Susp Dump, Mirrors

NOTE: Be sure the vehicle has 120 PSI air pressure, or some optional equipment may not function.

1. (If present) Verify proper function and or condition of:

   1. Steering Wheel/ Tilt Steering Wheel

   2. Differential Locks should lock, and release properly as denoted by auditory engagement and disengagement.

   3. Power Divider should lock, and release properly as denoted by auditory engagement and disengagement.

   4. Rear Air Suspension Dump (option)- rear frame lowers and raises as selected.

   5. Mirror, manual or motorized?

2. Document items to be repaired on PDI Report.

   1. Windows - open/ close properly — no damage

      1. Windows should open and close properly without binding, chattering, or excessive effort.

      2. Verify Bus Emergency Exit Windows open easily and fully and have decals affixed.

      3. Document items to be repaired on PDI Report.

13.31 Interior components and floor mat - condition, secure

1. Verify Interior components are neat and fit properly.

2. Verify Interior components are clean.

3. Verify Interior components are well secured.

4. Document items to be repaired on PDI Report.

13.34 Restraints, seats, windows, mirrors

1. Verify Proper installation, anchorage, condition, and operation of:

   1. Seats and Seat Belts.

   2. Windows and windshield

   3. Mirrors/ Electric Mirrors

2. Document items to be repaired on PDI Report.

13.36 Trainer Seats/Restraints option- installation condition

1. Verify Proper installation and condition of Seats and Seat Belts.

2. Document items to be repaired on PDI Report.

13.39 Driver’s Seat/ Restraints - secured, condition, functional

1. Verify Proper installation, condition, and operation of Seats and Seat Belts.

2. Document items to be repaired on PDI Report.

13.40 Driver’s Area - restraints, seat, windows, mirrors

1. Verify proper installation, condition, and operation of:

   1. Seats and Seat Belts.

   2. Windows and windshield

   3. Mirrors/ Electric Mirrors

2. Document items to be repaired on PDI Report.

13.50 Camera – Back up camera option–functional, secure

1. Camera should function while transmission is in reverse

2. Camera and monitors mounting and wiring should be well secured

3. Document items to be repaired on PDI Report.

13.58 Clear Inactive Fault Codes

1. Observe and document as-received fault codes using ECM image with Engine software.

2. Clear inactive fault codes.

3. Document active fault codes on PDI Report and complete associated repairs prior to Road Test if necessary.

13.64 Starter only Cranks in P or N

Automatic Transmission:

1. Select all gear ranges and turnkey to START position. Starter MUST NOT ACTIVATE except in NEUTRAL or PARK position.

2. Place transmission in drive or reverse. Shut off truck. Confirm shifter automatically returns to neutral upon key cycle.

3. Start vehicle.

4. Document items to be repaired on PDI Report.

13.67 Starter only Cranks in P (test 12V starter)

13.70 Turn off engine

15.10 Hydraulic Fluid Level

1. The fluid level should be within the acceptable fluid range.

2. Boom and cab should be in down position when testing filling.

3. DO NOT OVERFILL.

NOTE: If fluid level is in acceptable operating range, further fluid additions are not covered by PTD Warranty. Only fluid added, not labor, is covered by PTD Warranty.

15.20 Automatic Transmission Fluid Level - in COLD range

1. With vehicle transmission/ coolant cold and vehicle running and in neutral or park position, check transmission fluid level. Fluid level should register in COLD range.

2. Add appropriate fluid as needed to correct fluid level.

NOTE: If fluid level is in acceptable operating range, further fluid additions are not covered by PTD Warranty. Only fluid added, not labor, is covered by PTD Warranty.

15.40 Coolant Level - above mid-range/ lower view eye

1. Verify acceptable COLD Coolant level:

   1. View-Eye equipped Surge Tank:

      • Coolant level must at least cover the lower view-eye on Surge Tank.

2. Add compatible type of coolant as needed.

3. Check antifreeze protection level. Record Glycol Protection degree.

NOTE: Use a 50/50 mix of coolant and water or a 50/50 pre-mix.

NOTE: If fluid level is in acceptable operating range, further fluid additions are not covered by PTD Warranty. Only fluid added, not labor, is covered by PTD Warranty.

15:45 Engine Fan

1. Check fan operation. Fan should Engauge at 200-degree engine temp if optioned with Horton fan clutch. This needs to be tested with the AC turned off.

2. Check that the engine fan clutch engages when AC is turned on.

3. Check for clearance of shroud / baffles will not interfere with fan operation.

17.00 DRIVING TEST -

1. Pre-Planned Road Test Course should be nominally 6 miles (10km) and should include

   1. Test forward and reverse operation

   2. Full lock turns in right and left directions.

   3. Road speed should not exceed the Federal guideline of 24mph on off road applications or 33 mph for on road applications.

   4. A section of rough pavement to evaluate squeaks, rattles, rides, etc.

2. Before starting the Driving Test:

   1. Be sure the Battery Charger has been disconnected and the Battery Box Cover and Chassis Skirts have been reinstalled.

   2. Be sure the Bumper, Hood, Luggage Doors, Passenger Door, Trailer connections, etc. are securely fastened/ closed.

   3. Be sure the vehicle has enough fuel to complete the test.

17.05 Bump Track + Dyno or Road Test - No Concerns

1. Verify documentation shows Bump Track plus Dyno Tests or a Road Test was successfully completed. Bump Track + Dyno or a Road Test should verify among other things:

   1. Absence of squeaks, rattles, unusual noises, vibration, abnormal ride quality

   2. Steering wheel alignment correct(ed)

   3. Driver’s controls operating properly

   4. Full lock turns in right and left directions.

NOTE: If using Bump Track test only, perform 360-degree right and left hand turns at 5+ mph to force liquid axle lubricant into rear wheel hubs prior to axle lube level check.

1. Document items to be repaired on PDI Report.

17.13 Parking Brake - holds, releases

1. With Parking Brake set and engine at idle and transmission in 1st gear attempt to move vehicle. Vehicle must not move.

2. With the area clear, Parking Brake released, engine at idle, and transmission in 1st gear, attempt to move vehicle. Vehicle should move.

3. Document items to be repaired on PDI Report.

17.15 Trailer air lines

1. Check trailer air lines. All tractors are equipped with a trailer supply airline and trailer service brake airline. The supply line is red and the service line is blue.

2. Confirm proper orientation and operation of these lines.

3. Install dummy glad hands and test for leaks.

4. With lines capped off. Move vehicle forward and reverse to ensure drive axle brakes are free and operational.

17.22 Brake warning light, buzzer, motor, air brake tests

WARNING – Always chock the wheels before manually releasing the parking brakes, otherwise the vehicle could roll, causing property damage, personal injury, or death.

AIR BRAKE SYSTEMS:

1. Low Pressure Alarm turns off

   1. Assure vehicle will not roll, using chocks, and then release Park Brake and Service Brakes.

   2. With the key switch in the OFF position, the light must be off. The pressure reading in at least one air pressure gage must be below 55 psi. If necessary, cycle service brake pedal until the system pressure in both air pressure gages drops below 55 psi.

   3. Turn the key switch to the ON position. The low air pressure light and or buzzer must be on when the air pressure is below 55 psi.

   4. Start the engine and let it run. The light and buzzer must go off once the pressure readings in the air pressure gage with the lowest reading is between 55 and 76 psi.

2. Pressure Build

   1. Rev engine to maximum RPM. Pressure should build from 85 - 100 psi in 25 seconds or less.

   2. The governor should cut out air pressure building when gauge reading of 120 to 130 psi.

3. Pressure Bleed

   1. Turn OFF engine, switch key to ON position, release service brake.

   2. Air pressure reading in either air pressure gage should drop no more than 2 psi in one minute.

   3. Fully apply and hold service brake pedal.

   4. Air pressure reading in either air pressure gage should drop no more than 3 psi in one minute.

4. Low Pressure Alarm

   1. Cycle service brake pedal to deplete air pressure.

   2. Alarm must sound if the reading in either air pressure gage drops below 70 psi.

5. Park Brake Application

   1. Continue cycling service brake pedal to deplete air pressure

   2. Park brake must apply when the reading in air pressure gage #2 drops below 50psi.

6. Document items to be corrected on PDI Report.

17.25 Gear Selector/ Switches — functional

Automatic Transmission

1. Verify service brake must be depressed to move from Neutral to Drive or Reverse.

2. Verify that all gears are selected and achieved.

   1. Verify the applicable console-mounted Automatic or Automated Manual Transmission Shift Switches are functional - Neutral, Drive, Reverse, Hold, Upshift, Downshift, MANUAL/AUTO override shift switches, MODE, etc.

3. Document items to be repaired on PDI Report.

17.31 Horns — functional

1. Verify functionality of Steering Wheel Switches and Shift Console Switches

   1. Air horn (May be lanyard activated)

   2. Electric horn

2. Document items to be repaired on PDI Report.

17.37 Driver Controls — functional

1. Check for proper function of systems:

   1. Service brake

   2. Accelerator

   3. Steering

   4. Self-Cancelling Turn Signal

   5. Power Divider Lock

   6. Differential Locks

   7. Air Suspension Dump (optional)

2. Document items to be repaired on PDI Report.

17.40 Gauges and Warning Lamps — functional, no warnings

1. While in motion, with vehicle warmed up, check for proper function of gauges:

   1. Speedometer

   2. Oil Pressure

   3. Water Temperature

   4. Voltmeter

   5. Air Pressure

   6. Fuel level

   7. DEF Gauge

   8. Hour meter (On side of cab)

2. Verify no warning lamps are illuminated

3. Document component defects to be repaired on PDI Report.

17.43 Engine, Transmission, Brakes, Steering - performance

1. The following characteristics should be considered:

   1. Idle quality - smooth

   2. Acceleration - smooth and powerful; Accelerator Pedal operates smoothly.

   3. Shifts:

      • Automatic Trans - shifts crisp but not harsh

   4. NVH (Noise, Vibration, and Harshness) - smooth and quiet, no shuddering, squeaking, buzzing, hissing, whining.

   5. Braking (Service Brakes, )- smooth and powerful

   6. Steering - Tight and straight, no pull or vibration

   7. Oil Pressure - 25 - 50 psi, engine warm

   8. Water Temperature - 225 F (107 C) max, engine hot

   9. Volts - 13.0 - 15.0 Volts

2. Each parameter should be within an acceptable range per vehicle type and class.

3. Perform full left to right lock to lock turns to set steering and purge air from PS fluid.

4. Document items to be repaired on PDI Report.

17.52 Auxiliary Gear Selectors - function

1. Gear selector should select correct gear in each gear selector position

2. Document items to be repaired on PDI Report.

17.55 Steering Wheel Alignment - straight +/- 3/4" (18 mm)

NOTE – If the vehicle pulls significantly to the left or right, the axles may be out of alignment. Do not attempt to reposition an off-center steering wheel until axle alignment is deemed to be proper.

1. If the axle alignment is deemed acceptable, verify the location of the steering wheel rim centerline is off-center by less than 3/4" (18 mm) for an 18-inch wheel.

2. Re-align the steering wheel as part of PDI if steering wheel alignment is out of spec.

Adjustment Specifications Chart:

72 Tooth Spline Steering Wheel:

• The 72 tooth spline steering wheel can be adjusted by +/- 5 degrees.

• 18 inch wheel - each tooth = 3/4 inch at the outside of the wheel.

NOTE: Labor to adjust steering wheel alignment is included in PDI.

1. Document items to be adjusted/ repaired (including axle alignment) on PDI Report.

NOTE – Labor for intentionally misaligning the steering wheel to meet a special customer request is not covered under PDI or PTD Warranty, but is to be charged towards the purchase cost of the vehicle.

17.58 Steering Wheel Alignment — straight per spec

NOTE – If the vehicle pulls significantly to the left or right, the axles may be out of alignment. Do not attempt to reposition an off-center steering wheel until axle alignment is deemed to be proper.

1. If the axle alignment is deemed acceptable, verify the location of the steering wheel rim centerline is off-center by less than 3/4" (18 mm) for an 18-inch wheel, or less than 7/8" (22 mm) for a 20-inch wheel.

NOTE – Labor for intentionally misaligning the steering wheel to meet a special customer request is not covered under PDI or PTD Warranty but is to be charged towards the purchase cost of the vehicle.

17.64 Wind noise - no leaking body seals

1. Verify there is no unusually excessive wind noise or water leaks if raining.

2. Document items to be corrected on PDI Report.

17.67 Climate Controls - Fan Speed, Temperature, Ducts

1. Check for proper operation of:

   1. Heater

   2. Defroster

   3. A/C (option)

   4. Blower Fan

   5. Adjustable Vents

   6. Auxiliary fans (option)

2. Document component defects to be repaired on PDI Report.

17.70 Wheels and Tires

1. Check tire pressures are set to manufacture specifications.

2. Torque all wheel lug nuts:

3. Check tire clearance between tires and chassis while turning fully right and left. Minimum clearance is one inch.

4. Document component defects to be repaired on PDI Report.

17.75 Hydraulic system

1. Check for leaks and loose fasteners: check for loose clamps and fittings as well as routings,

2. Torque Fifth wheel mounting bolts to 180ft lbs. / Nuts to 130ft lbs.

3. Check hydraulic oil level: cycle 5^th wheel boom up and down twice before checking fluid level. If fluid level is at bottom of fill neck screen or between lines on dipstick (where applicable) when boom lowered. Additional fluid is not needed.

4. Check hydraulic cylinders: check fittings and seals and hose routing

5. Check stops are pressed up against lower cylinder mounts.

6. Check hydraulic cylinder rod ends: check clamp bolts for tightness, torque valves on nuts should fall between 50 and 55 ft lbs.

7. Check 5^th wheel operation: check coupling and unlatch valve for proper operation.

17.82 Turn Off Engine

19.10 Hot Coolant Level: MAX +/- 1" or above lower view eye

1. After the Drive Test, Hot coolant level should register within +/- 1" (25 mm) of MAX indicator on surge tank sight glass. Coolant should not be overflowing.

2. Check over all heater and radiator hose connections for loose / leaking signs.

3. Add coolant only if outside this range.

WARNING – To avoid being scalded by hot coolant, wait until engine cools and then slowly unscrew surge tank cap if necessary.

NOTE: Use a 50/50 mix of coolant and water or a 50/50 pre-mix..

..

19.40 Automatic Transmission Fluid Level - in HOT range

NOTE: This test can only be done immediately after the Drive Test with transmission at operating temp.

1. With the vehicle running and in neutral or park position, check transmission fluid level. The fluid level should register between midpoint and FULL mark in HOT range.

2. Add or drain appropriate fluid as needed to correct fluid level.

NOTE: If fluid level is in acceptable operating range, further fluid additions are not covered by PTD Warranty. Only fluid added, not labor, is covered by PTD Warranty.

19.45 Battery & Alternator Test using Midtronics EXP

1. Verify Battery, Starting Voltage and Alternator Output is acceptable using Midtronics Intellect EXP electrical charging system tester.

2. Document items to be repaired or programmed on PDI Report.

19.50 Coolant Freeze Point: protection to -34 (-37C) or lower

Verify coolant Freeze point is -34 F to -42 F ( -37 C to -41 C) using a refractometer and adjust concentration as necessary by adding coolant concentrate or de-mineralized water to obtain specified freeze point.

19.60 No Fluid, Exhaust or Air Leaks - entire vehicle

NOTE: It is recommended that the appropriate detector (ultrasonic leak detector (required tool) or refrigerant sniffer) is used in addition to normal hearing, sprayed-on soap solution on suspect components, or visual signs of leakage.

1. With Vehicle running inspect exhaust connections and CAC / intake hosing for audible or visible leakage.

2. Check the circumference of each rubber connector for folded over portions or loose clamps.

3. Return vehicle to a quiet inspection bay where small air leaks can be heard.

4. Install wheel chocks.

5. Turn OFF key.

6. Release parking brake. (This pressurizes additional air hoses)

7. Apply Service Brakes during the inspection using a prop-rod between the driver’s seat and the brake pedal.

8. Verify there are no visible fluid, exhaust, or audible air leaks anywhere on the vehicle. Items included in check: (HVAC condensate (water) is not included as that is desirable)

   1. Refrigerant hoses - as evidenced by localized oil mist on hose, sender, or fitting

   2. Air hoses

   3. Fuel hoses, Fuel Tank, Fuel Delivery System

   4. Radiator

   5. Coolant / heater/ in-transit heat hoses

   6. Power steering reservoir and hoses

   7. Transmission cooler and hoses

   8. Engine

   9. Transmission

   10. Drive Axles

   11. Wheel Seals

   12. Hydraulic boom hoses/ cylinders.

9. Verify manual operation of air tank drain valves.

10. Check that muffler / tailpipe assembly is still clamped and positioned correctly.

11. Document items to be corrected on PDI Report.

21.10 Diagnostic Health Report

1. Connect Diagnostic Tool to Vehicle

2. Run eTechnician and export Health Report and attach to PDI case

3. Run Vodia if Electric Driveline from Volvi Penta and attach to PDI case

21.11 Traction Voltage - Check Battery Charging Operation

1. Review procedure from Volvo Penta Partner Network, Workshop Manual, procedure, Traction Voltage System, Commissioning

21.20 Operator’s Manual, other required documents present

1. Supporting documents potentially required by law including:

   1. Truck Chassis Operator’s Manual

2. Other documents that may be present:

21.70 ADD COMMENTS TO PDI REPORT

1. Document details of problems/corrections made during PDI

2. Document details of repairs to be made, open Recalls, open SFNs, Uptime issues.

3. Check off completed repairs.

4. Include any applicable R.O. numbers if desired.