Volvo F16 Truck Service and Repair Manual PDF
Size: 194.81 MB
Language: English
Make: Volvo
Machine: Truck
Document: Service and Repair Manual, Schematic Diagram
Model: Volvo F16
Description
Volvo F16 Truck Service and Repair Manual PDF
Size: 194.81 MB
Language: English
Make: Volvo
Machine: Truck
Document: Service and Repair Manual, Schematic Diagram
Model: Volvo F16
Page: 3437 Pages
Detail Contents:
Bulletins – Information
- 9990008 Set of Test pins 1
9990008 Set of Test pins
9992876 Spacer sleeve
Modification of cable harness for new brake contacts or horn
Description, Design and Function
- Air suspension, system description
Anti-lock brake system (ABS)
Anti-roll bar, rear
Automatic transmission
Ball nut
Ball worm
Basic gearbox
Basic housing
Bogie lift 1
Bogie lift 2
Bogie lift 3
Cab 1
Cab 2
Cab suspension 1
Cab suspension 2
Clutch linkage
Component descriptions
Compressor 1
Compressor 2
Control housing
Control system components
Cooling system
Diaphragm spring
Diff, lock
Differential carrier, section view
Differential carrier
Disassembly instructions, complete vehicle
Disc
Double disc clutch
Driving EDC-equipped trucks
EDC system, function
Electrical system
Engine cover 1
Engine cover 2
Feed pump
Front air suspension, components 1
Front air suspension, components 2
Front hub, components
Fuel level sensor
Gear box, manual 1
Gear box, manual 2
Gear box, manual 3
Gear box, manual 4
Gear box, manual 5
Gear box, manual 6
Gear box, manual 7
Gear box, manual 8
Gearbox construction
General 1
General 2
General 3
General 4
General 5
General 6
General 7
General 8
General 9
General
Hand primer
Heating unit
Hub reduction, exploded view 1
Hub reduction, exploded view 2
Hub reduction, overhaul (one side)
Hub reduction, section view
Hydraulic system, general
Injection pump 1
Injection pump 2
Injection pump
Injector
Injectors
Intake system
Introduction
KOMPR155
LP48ESS
Lube oil pump
Lubrication and oil system
Lubrication system
Oil flow path during steering
Oil flow path during unloading
Operating piston
Operating system, components
Outside sun-visor 1
Outside sun-visor 2
Pneumatic system
Position diagram, ABS
Power path 1
Power path 2
Power steering gear, exploded view
Power steering pumps, exploded view 1
Power steering pumps, exploded view 2
Power take-off 1
Power take-off 2
Power take-off
Pressure limiting valve (pos 51)
Propeller shaft
R3 – Group 211 212 213
R3 – Group 230 236 233 237
R3 – Group 250 253 255 256 266
R3 – Group 260 262
R3 – Group 432
R3 – Group 593
R3 – Group 601 640 641
R3 – Group 601 640 641-1
R3 – Group 642
R3 – Group 818 Rear cab mounting
R3 – Group 831 832
R3 – Group 860
Range gear
Rear axle, general 1
Rear hub, components
Reinforced transfer gear
Release bearing
Roof hatch 1
Roof hatch 2
Sector shaft
Shift mechanism SR1400 1700
Single disc clutch
Smoke limiter
Spring cradle and stay
Steering arm, replace (one) 1
Steering arm, replace (one) 2
Steering knuckle, exploded view 1
Steering knuckle, exploded view 2
Steering knuckle
Steering wheel adjustment
Stop control, pneumatic
Straps
Symbol index
The ESS function
Towing information
Trailer brake circuit F
Transfer gear, 1
Transfer gear, 2
Tyre and inner tube
Unloading mechanism
Vehicle Identification Number VIN
Voltage regulator
VSP program
VSP
V-stay, reaction rod rear end
Wheel alignment 1
Windscreen 1
Windscreen 2
Wings
Diagnostics
- Adjusting measured voltages
Air conditioning, test performance
Ball joint, link rod and track rod, axial play, check
Basic check of cruise control
Battery analyser, 7200, user manual
Battery analyzer, 88890075 EXP, user manual
Cables and connectors, fault tracing
Check of speed limiter, FH vehicles
Check of speed limiter, FL, FS, F, NL, N vehicles
Check of the tachograph’s speedometer, FH vehicles
Check of the tachograph’s speedometer, FL, FS, F, NL, N vehicles
Checking break contact
Checking engine performance
Checking fuel cut-off function
Checking speed limiter
Checking the bogie lift and bogie press functions
Compressor, function and leakage check
Diagnostic lamp
Dual draw dual return fuel system troubleshooting
Expected values
Fault codes
Fault tracing procedures
Fuel system and used lubricant oil analysis, fault tracing
Fuel system, fault tracing
Fuel system
Function check of cruise control and constant engine speed
Gearbox fault codes reading, check connection with VOLVO diagnostic tool
General EV87
General
Hydraulic system, fault tracing
Inductive sensor
Injection timing device, function check
Interpreting results
Level control
Malfunction, probable causes and recommended action
Malfunctions, causes and remedial actions 1
Malfunctions, causes and remedial actions
Malfunctions, probable causes and procedures
Measuring with vehicle moving
Measuring with vehicle stationary
Power steering, function check
Power take-off (gearbox)
R3 – Group 32
R3 – Group 64
R3 – Group 561
Ready-reference, fault codes
R-SR-SRO1000-2400
Simplified function check
Status tests
Test instrument for checking
Thermostat controlled fan, function check
Timer relay 3017
Timer relay 3017-1
VSP
Repair
- 60110-2 Wheel angles, check-measure (all)
60124-2 Toe-in, check
60131-3 Toe-in, adjust
61002-2 Front end wear, check
61103-3 Steering knuckle, overhaul (one)
61270-1 Front axle complete, remove
61272-1 Front axle complete, install
61903-1 Cross member front, remove
61904-4 Cross stay front, overhaul
61905-1 Cross stay front, install
64104-2 Steering wheel, replace
64106-2 Steering shaft bearings upper and lower, replace
64116-2 Steering shaft universal joint, replace
64120-2 Steering wheel adjuster, adjust
64122-2 Steering wheel adjuster, overhaul
64210-2 Sealing ring, steering spindle, replace
64252-2 Pressure point, steering gear, check and adjust1
64252-2 Pressure point, steering gear, check and adjust2
64254-2 Unloading mechanism, check and adjust1
64254-2 Unloading mechanism, check and adjust2
64282-1 Steering gear, remove
64284-1 Steering gear, install
64305-5 Pitman arm, replace
64312-2 Link rod, replace
64357-5 Track rod end, replace (one)
64370-1 Track rod, remove
64512-4 Power steering pump, overhaul
64570-1 Servo pump, remove
64572-1 Servo pump, install
65212-2 Bushings, reaction rod, replace (one side)
65246-2 Bushings, front reaction rod, replace (one side)
65270-1 V-rod, remove
65271-5 V-rod, outer ball joint, overhaul
65272-1 V-stay rod, install
65273-5 V-rod, centre joint, overhaul1
65273-5 V-rod, centre joint, overhaul2
65516-4 Spring cradle, overhaul1
65516-4 Spring cradle, overhaul2
65525-3 Shaft, spring cradle, replace1
65525-3 Shaft, spring cradle, replace2
65570-1 Spring cradle, remove1
65570-1 Spring cradle, remove2
65570-1 Spring cradle, remove3
65572-1 Spring cradle, install1
65572-1 Spring cradle, install2
65747-4 Hydraulic cylinder, bogie lift, overhaul
72508-2 Front anchorage, reaction rod, replace
72514-2 Level valve, front axle, setting
72515-2 Level valve, non-return valve and control valve, replace
72602-2 Air bellows, drive axle, replace
72603-2 Air bellows, driven axle, check
72604-2 Levelling valve drive axle, replace (one)
72612-2 Highest control position rear, adjust
72616-2 Bellow plate, rear, replace
72625-4 Level valve, basic setting
72627-4 Level valve, overhaul
72636-2 Level valve, non-return valve and control valve, replace
72840-4 Solenoid Valve, Air Suspension, Overhaul
76204-2 Rubber journal and bushing, anti roll bar front, replace
76436-2 Levelling valves, rear axle, setting
77101-2 Spoke wheel, replace
77102-2 Disc wheel, replace
77103-3 Disc wheel, check
77145-3 Wheel nuts, check tightening (all)
77334-2 Rear wheel bearing, adjust (one wheel)1
77334-2 Rear wheel bearing, adjust (one wheel)2
77343-3 Wheelstud, replace
77363-2 Rear wheel bearing and seal, replace1
77363-2 Rear wheel bearing and seal, replace2
77363-2 Rear wheel bearing and seal, replace3
81801-2 Tilt cylinder, replace
81802-2 Cab tilt pump, replace
81804-2 Tilt cylinder, re-gasket
81811-4 Anti-roll bar shaft, remove
81813-4 Bushing anti-roll bar, replace
81814-2 Cab tilt pump, re-gasket
81815-4 Anti-roll bar shaft, install
81818-2 Rear spring, replace (two)
81820-2 Cab shock absorber rear, replace (one)1
81820-2 Cab shock absorber rear, replace (one)2
81822-2 Shock absorber front, replace (two sides)
81826-2 Cab shock absorber rear, replace (two)
81828-2 Cab tilt pump, pressure checking
81870-1 Cab, remove1
81870-1 Cab, remove2
81870-1 Cab, remove3
81872-1 Cab, install1
81872-1 Cab, install2
81872-1 Cab, install3
82130-2 Bonnet, remove-install1
82130-2 Bonnet, remove-install2
82310-2 Radiator grille, replace1
82310-2 Radiator grille, replace2
82310-2 Radiator grille, replace3
82514-2 Front mudguard, front section, replace
82540-2 Front mudguard, rear, replace (two sides)1
82540-2 Front mudguard, rear, replace (two sides)2
83131-2 Door stop, replace1
83131-2 Door stop, replace2
83131-2 Door stop, replace3
83138-2 Door hinges, adjust (one door)1
83138-2 Door hinges, adjust (one door)2
83145-2 Door guide, adjust (one)1
83145-2 Door guide, adjust (one)2
83402-2 Door handle inside, replace
83404-2 Door handle outside, replace1
83404-2 Door handle outside, replace2
83404-2 Door handle outside, replace3
83408-2 Lock cylinder, replace (one)
83414-2 Door lock, replace (one side)1
83414-2 Door lock, replace (one side)2
83414-2 Door lock, replace (one side)3
83505-2 Window lift, replace
83610-2 Roof hatch, replace1
83610-2 Roof hatch, replace2
83613-2 Roof hatch springs, replace (all)1
83613-2 Roof hatch springs, replace (all)2
84150-2 Reflector, replace
84232-2 Decor stripes, new install (complete kit)1
84232-2 Decor stripes, new install (complete kit)2
84302-2 Windscreen, replace1
84302-2 Windscreen, replace2
84302-2 Windscreen, replace3
84406-2 Door window, replace1
84406-2 Door window, replace2
84406-2 Door window, replace3
84416-2 Ventilation window, replace1
84416-2 Ventilation window, replace2
84602-2 Heater plate rear view mirror, replace
85150-1 Door upholstery, remove1
85150-1 Door upholstery, remove2
85150-1 Door upholstery, remove3
85151-1 Door upholstery, install1
85151-1 Door upholstery, install2
85151-1 Door upholstery, install3
85226-1 Driver’s seat, remove1
85226-1 Driver’s seat, remove2
85227-1 Driver’s seat, install1
85227-1 Driver’s seat, install2
85228-4 Driver’s seat shock absorber, replace1
85228-4 Driver’s seat shock absorber, replace2
85278-2 Seat height level control valve, replace1
85278-2 Seat height level control valve, replace2
85505-1 Headlining, install1
85505-1 Headlining, install2
85505-1 Headlining, install3
85507-1 Headlining, remove1
85507-1 Headlining, remove2
85507-1 Headlining, remove3
85570-1 Roof upholstery front, remove
85572-1 Roof upholstery front, install
85574-1 Roof upholstery rear, remove
85576-1 Roof upholstery rear, install
86103-2 Bumper, replace1
86103-2 Bumper, replace2
86103-2 Bumper, replace3
86103-2 Bumper, replace4
86180-1 Bumper, remove
86181-1 Bumper, install
87001-3 Refrigerant air conditioning system, fill1
87001-3 Refrigerant air conditioning system, fill2
87002-2 Refrigerant, topping up
87004-2 Refrigerant, draining and re-using
87010-1 Air conditioning system, remove1
87010-1 Air conditioning system, remove2
87012-1 Air conditioning system, install1
87012-1 Air conditioning system, install2
87012-1 Air conditioning system, install3
87152-2 Heater control panel, replace
87208-3 Air conditioning air filter, replace
87306-2 Air conditioning blower motor, replace
87347-5 Heat exchanger, replace
87352-2 Temperature sensor, instrument panel, replace
87354-2 Temperature sensor, air conditioning system, replace
87356-2 Temperature sensor behind air cleaner, replace
87358-2 Temperature sensor, evaporator, replace
87360-2 Ejector, replace
87362-2 Solenoid valve, replace
87364-2 Heater control valve, replace
87366-2 Control unit, replace
87402-2 Evaporator, replace
87403-2 Refrigerant, draining
87404-2 AC compressor, replace
87407-2 Refrigerant, changing (from r12 to 134a)
87408-2 Condenser, replace1
87408-2 Condenser, replace2
87410-2 Receiver drier, replace1
87410-2 Receiver drier, replace2
87412-2 Thermostat, replace1
87412-2 Thermostat, replace2
87431-5 Evaporator, replace
87435-5 Expansion valve, replace
87438-4 Shaft seal, replace
87440-4 Valve plate, replace
87442-4 Compressor clutch, replace
87470-1 Compressor, remove
87472-1 Compressor, install
88408-2 Seat belt, replace (one)1
88408-2 Seat belt, replace (one)2
89110-2 Sun visor complete, replace1
89110-2 Sun visor complete, replace2
89114-2 Wind deflector, new install
Accelerator pedal, contact, adjust
Adjusting the differential lock indication
Air cylinder, fuel shut-off, replace
Air drier insert, replace
Air drier, drier insert, replace 1
Air drier, drier insert, replace 2
Air drier, overhaul 1
Air drier, overhaul 2
Air-drier preheating element, replace
Alternator, disassembly
Alternator, installation
Balancing the propeller shaft
Basic setting of speed limiter control
Basic setting, chec with measuring instrument
Bearing bushings, injection timing adjuster, replace
Bearing, fan attachment, replace
Before check-measuring
Bogie lift valve, overhaul
Brake cylinder, overhaul (single diaphragm)
Camshaft bearing, replace
Camshaft wear, check
Camshaft, replace
CD-ROM Reader to disc drive, changing
Check, wear in cam housing
Clutch cylinder, replace 1
Clutch cylinder, replace 2
Clutch fork and clutch shaft, replace
Clutch pedal, contact, adjust
Clutch plate, marking
Clutch plate, replace 1
Clutch plate, replace 2
Clutch plate, replace 3
Clutch servo, adjust
Clutch servo, overhaul 1
Clutch servo, overhaul 2
Clutch servo, overhaul 3
Clutch system, bleed
Clutch, check and replacement of components
Clutch, wear check
Collector ring, replacement
Compressor loading time, check
Compressor magnetic clutch, assembly
Compressor magnetic clutch, disassemble
Compressor piston rings, replace 1
Compressor piston rings, replace 2
Compressor, check and wear measurement
Compressor, overhaul 1
Compressor, overhaul 2
Compressor, replace
Connecting rod bearings, replace (all)
Control cylinder for high and low gear ranges, overhaul 1
Control cylinder for high and low gear ranges, overhaul 2
Control housing, overhaul
Control lamp, replace
Control unit, replace
Control valve, overhaul
Coolant distributor pipe, replace
Coolant pump, overhaul 1
Coolant pump, overhaul 2
Coolant pump, replace
Cooling system, clean
Cooling system, drain and refill
Cooling system, pressure test
Countershaft, overhaul 1
Countershaft, overhaul 2
Crankshaft seal, replace (rear)
Crankshaft, inspection and overhauling
Crankshaft, replace
Cylinder block, face grind
Cylinder compression test
Cylinder head sealing grooves, cut (each)
Cylinder head, assemble
Cylinder head, disassemble
Cylinder head, face grind
Cylinder head, install (first)
Cylinder head, pressure test (first)
Cylinder head, remove (first)
Cylinder liner seat, milling (first)
Delivery pipes, replace (all)
Diaphragm sleeve, adjust
Diff lock, check and adjust disengage and engage position
Differential carrier, install
Differential carrier, overhaul
Differential carrier, remove
Drive shaft oil pump, assemble shaft and gear wheel
Engine turbocharger, replace
Engine, install
Engine, remove
Exhaust pressure governor, overhaul
Exhaust pressure governor, replace
Failure diagnosis
Feed pump, replace
Filter insert, air cleaner, replace
Flywheel bearing, replace
Flywheel housing run-out, check
Flywheel housing, replace
Flywheel ring gear, replace
Flywheel, check
Flywheel, replace
Footbrake valve, overhaul
Four circuit protection valve, overhaul 1
Four circuit protection valve, overhaul 2
Front axle member (removed), check measuring
Fuel feed pressure, check
Fuel feed pump, overhaul
Fuel filters, replace (two)
Fuel pipes, staying
Fuel system, bleeding
Fuel system, check
Fuel tank strainer, clean and drain condensation water
Gaskets, exhaust manifold, replace
Gaskets, intake manifold, replace
Gaskets, timing gear cover, replace
Gear lever carrier, overhaul
Gear lever knob, overhaul
Gear shift mechanism, adjust
Gear wheel axle shaft oil pump, replace
Gearbox, disassemble-inspect-assemble
Gearbox, install
Gearbox, remove
Gudgeon pin bushings, changing
Hub reduction, overhaul (one side)
Inhibitor valve range housing, overhaul
Inhibitor valve shift housing, overhaul
Inhibitor valve splitter gear, overhaul
Injection pump drive shaft seal, replace 1
Injection pump drive shaft seal, replace 2
Injection pump, adjust
Injection pump, check on test bench
Injection pump, install 1
Injection pump, install 2
Injection pump, remove 1
Injection pump, remove 2
Injection pump, setting on engine
Injection timing adjuster, install
Injection timing adjuster, remove
Injector adjustment, recommendations
Injectors opening pressure, adjust (each)
Injectors, overhauling
Injectors, replace (all)
Input shaft, overhaul
Insect screen, new install
Installation of retarder function
Level control, adjustment
Main bearings, replace (all)
Main shaft, overhaul
Master cylinder for clutch complete, overhaul
Non-condensible gases, handling procedures
Oil cooler, pressure test
Oil cooler, replace
Oil filter, engine, replace
Oil pressure, check
Oil pump, overhaul 1
Oil pump, overhaul
Oil pump, remove-install
Output shaft sealing ring, replace
Pinion sealing ring, replace
Piston and liner, replace (one)
Piston rings, inspection
Piston thermostat, replace
Piston, piston rings and connecting rod, fitting
Piston, piston rings and connecting rod, removing
Pistons, fit
Power take-off, install 1
Power take-off, install 2
Power take-off, overhaul 1
Power take-off, overhaul 2
Power take-off, remove 1
Power take-off, remove 2
Pressure drop indicator, check
Pressure governor, adjust
Pressure governor, overhaul 1
Pressure governor, overhaul 2
Pressure limiter valve, overhaul
Quick release valve (front), overhaul
Radiator, external cleaning
Radiator, replace
Range cylinder, adjust
Range cylinder, overhaul
Range gear, install
Range gear, overhaul 1
Range gear, overhaul 2
Range gear, overhaul 3
Range gear, remove
Relay valve range cylinder, overhaul
Relay valve split cylinder, overhaul
Relay valve, overhaul
Release bearing, pulling clutch replace 1
Release bearing, pulling clutch replace 2
Replacing bearings and seals
Replacing output shaft bearing 1
Replacing output shaft bearing 2
Retarder, fitting
Retroactive fitting of the corrugated plastic hose
Reverse shaft, overhaul
Rocker arm mechanism, overhaul
Safety rules1
Safety rules2
Seat, overhauling
Separate regulator, test
Sleeve, injector, replace (One)
Solenoid valve, air drier, replace
Split cylinder, overhaul
Splitter gear, check and adjust
Spring brake cylinder, overhaul 1
Spring brake cylinder, overhaul 2
Steering
Switch, differential lock, check and adjust
Tachograph speedometer, calibration
Temperature gauge, checking
Thermostat fan, replace
Thermostats, test 1
Thermostats, test
Timing gear casing, sealant changing
Timing gears, replace (all)
Trailer brake control valve, overhaul
Trailer brake control, overhaul
Trailer connection, replace
Turbo boost gauge, remove-install
Turbo failure on charge air cooler engines, inspect
Turbo-compressor, changing fitting to engine
Universal joint angles, check and calculate
Valve block, clutch control, changing
Valve guides, inspection
Valve guides, replace (one cylinder head)
Valve plate, replacement
Valve seat, replace (one)
Valve seats, grinding
Valves grind and decarb (first cylinder head)
Valves, adjust
Visual inspection
Working with chemicals
Schematic Diagrams
- Battery, warranty claim handling, additional information
Brake circuit diagram 1 FL-F 4X2 without trailer equipment
Brake circuit diagram 6X2
Brake circuit diagram 6X4
Brake circuit diagram 8X2
Brake circuit diagram 8X4
Brake circuit diagram
Manual gearbox, warranty claim handling, additional information
Service and Maintenance
- Annual service
Automatic speed limiter, setting
Basic service
Check of high pressure monitor
Checking and adjustment of reduction valve for exhaust pressure governor
Chemical products catalogue
Cleanliness in the clutch system
Cylinder head, inspection
Hydraulic pump, service
Lubrication chart
Oil filter protection
Oil pressure, check
Washing, polishing and waxing, cab
Specifications
- Air suspension, pneumatic components
Alternator
Axial play
Compressed-air tank
Compressor 704
Compressor
Cooling system 1
Cooling system 2
Cooling system 3
Crank mechanism 1
Crank mechanism 2
Crank mechanism 3
Cylinder head
Engine 1
Engine 2
Engine 3
Final drive 1
Final drive
Foot and hand controls
Front axle
Front axle1
Fuel system 1
Fuel system 2
Fuel system 3
General 1
General 2
General 3
General 4
Hubs, tightening torques
Intake and exhaust system 1
Intake and exhaust system 2
Intake and exhaust system 3
Lubricating and oil system 1
Lubricating and oil system 2
Lubricating and oil system 3
Oil pump
Pedal play
Performance curves 1
Performance curves 2
Performance curves 3
Power steering pump
Power take-off
Press forces 1
Press forces 2
Propeller shaft
Pulling clutch, double disc
Pulling clutch, single disc
R3 – Group 650
Rear axle 1
Rear axle 2
Servo pump with aluminium housing
Short stroke synchronization
Specifications
Speed sensor with O-ring
Steering gear
Steering wheel, steering shaft and steering shaft adjustment 1
Steering wheel, steering shaft and steering shaft adjustment 2
Syncronizer 1
Syncronizer 2
Tightening torques 1
Tightening torques 2
Tightening torques 3
Tightening torques 4
Tightening torques 5
Transfer box
Tyre and inner tube
Valve mechanism 1
Valve mechanism 2
Valve mechanism 3
VCADS, VSP and Brake Adaptation, CD
Wear tolerances 1
Wear tolerances 2
Wear tolerances 3
Wheel alignment
Wheel