Volvo N12 Truck Service and Repair Manual PDF

Volvo N12 Truck Service and Repair Manual PDF

Size: 98.87 MB
Language: English
Make: Volvo
Machine: Truck
Document: Service and Repair Manual
Model: Volvo N12
Page: 2433 Pages

Detail Contents:
17523-3 Gearbox oil and filter, replace
17527-3 Final drive oil, change
17528-3 Retarder, oil change
17530-3 Transfer gearbox, oil change
17561-3 Final drive with hub reduction, oil change
17577-3 Power take-off, oil and filter, change
17582-3 Driven front axle, oil change
17725-3 Driver’s service, optional
17746-2 Annual service
21002-2 Cylinder compression test
21105-5 Valve seat, replace (one)
21170-1 Cylinder head, remove (first)
21171-4 Cylinder head, pressure test (first)
21172-1 Cylinder head, install (first)
21173-5 Cylinder head sealing grooves, cut (each)
21177-4 Cylinder head, transfer parts
21192-5 Cylinder head, face grind
21233-3 Flywheel housing, replace
21235-3 Flywheel housing run-out, check]
21261-5 Cylinder block, face grind
21307-3 Cylinder liner seat, milling (first)
21357-3 Piston and liner, replace (one)
21373-5 Piston or gudgeon pin, replace
21375-4 Cylinder liner and piston, wear check
21412-2 Valves, adjust
21415-5 Valve guides, replace (one cylinder head)
21417-5 Valve guide wear, check
21491-4 Valves grind and decarb (first cylinder head)
21493-4 Rocker arm mechanism, overhaul
21516-2 Camshaft wear, check
21521-3 Camshaft, replace
21531-3 Timing gears, replace (all)
21603-3 Main bearings, replace (all)
21607-3 Flywheel bearing, replace
21611-3 Connecting rod bearings, replace (all)]
21617-3 Polygon hub, replace
21621-3 Flywheel, replace
21631-3 Flywheel, check
21635-5 Connecting rod bushing, replace (each)
21667-3 Crankshaft seal, replace (rear)
21692-5 Connecting rod, check
23378-2 Fuel feed pressure, check
23415-3 Fuel tank strainer, clean and drain condensation water
23604-2 Pump coupling disc, replace (first)
23701-5 Copper sleeve injector, replace (one)
23724-2 Delivery pipes, replace (all)
26106-2 Radiator, external cleaning
26202-2 Coolant pump, replace
26273-4 Thermostats, test
31102-2 Batteries, replace (all)
31122-2 Battery, state of charge, check (Measure specific gravity)
33104-0 Starter motor, replace
37130-2 Trailer connection, replace
38660-2 Impulse sender diff.lock indicator light, adjust 1
38660-2 Impulse sender diff.lock indicator light, adjust
41103-3 Clutch plate, replace 1
41103-3 Clutch plate, replace
41104-3 Clutch, wear check
41277-5 Clutch fork and clutch shaft, replace 1
41277-5 Clutch fork and clutch shaft, replace
41283-5 Release bearing, pulling clutch replace v1
41283-5 Release bearing, pulling clutch replace
41314-2 Clutch cylinder, replace 1
41314-2 Clutch cylinder, replace
41322-2 Master cylinder for clutch complete, overhaul
41342-2 Clutch system, bleed 1
41342-2 Clutch system, bleed
41375-4 Clutch servo, overhaul 1
41375-4 Clutch servo, overhaul 2
41375-4 Clutch servo, overhaul
43130-2 Output shaft sealing ring, replace
43137-3 Oil pressure, check
43156-2 Splitter gear, check and adjust
43214-2 Gear lever carrier, overhaul
43266-2 Range cylinder, overhaul
45122-2 Universal joint angles, check and calculate 1
45122-2 Universal joint angles, check and calculate 2
45122-2 Universal joint angles, check and calculate 3
45122-2 Universal joint angles, check and calculate
46514-2 Pinion sealing ring, replace 1
46514-2 Pinion sealing ring, replace 2
46514-2 Pinion sealing ring, replace 3
46514-2 Pinion sealing ring, replace 4
46514-2 Pinion sealing ring, replace
46540-2 Output shaft sealing ring, replace ev87
46540-2 Output shaft sealing ring, replace
46544-2 Output shaft bearing, replace 1
46544-2 Output shaft bearing, replace
46570-1 Differential carrier, remove 1
46570-1 Differential carrier, remove 2
46570-1 Differential carrier, remove 3
46570-1 Differential carrier, remove 4
46570-1 Differential carrier, remove 5
46570-1 Differential carrier, remove 6
46571-4 Differential carrier, overhaul 1
46571-4 Differential carrier, overhaul 2
46571-4 Differential carrier, overhaul 3
46571-4 Differential carrier, overhaul 4
46571-4 Differential carrier, overhaul 5
46571-4 Differential carrier, overhaul
46572-1 Differential carrier, install 1
46572-1 Differential carrier, install 2
46572-1 Differential carrier, install 3
46572-1 Differential carrier, install 4
46572-1 Differential carrier, install 5
46572-1 Differential carrier, install 6
46572-1 Differential carrier, install 7
46572-1 Differential carrier, install 8
46572-1 Differential carrier, install ev87
46572-1 Differential carrier, install
46656-2 Hub reduction, overhaul (one side) 1
46656-2 Hub reduction, overhaul (one side) 2
46656-2 Hub reduction, overhaul (one side) 3
46656-2 Hub reduction, overhaul (one side) nr2
46656-2 Hub reduction, overhaul (one side)
46802-2 Diff lock, check and adjust disengage and engage position 2
46802-2 Diff lock, check and adjust disengage and engage position 3
46802-2 Diff lock, check and adjust disengage and engage position 4
46802-2 Diff lock, check and adjust disengage and engage position 5
46802-2 Diff lock, check and adjust disengage and engage position
46803-3 Diaphragm sleeve, adjust 1
46803-3 Diaphragm sleeve, adjust 2
46803-3 Diaphragm sleeve, adjust 3
46803-3 Diaphragm sleeve, adjust 4
46803-3 Diaphragm sleeve, adjust
48170-1 Power take-off, remove 1
48170-1 Power take-off, remove
48171-4 Power take-off, overhaul 1
48171-4 Power take-off, overhaul
48172-1 Power take-off, install
51085-4 Brake cylinder, overhaul (single diaphragm)
51087-4 Spring brake cylinder, overhaul 1
51087-4 Spring brake cylinder, overhaul
56112-2 Pressure governor, adjust
56113-3 Pressure regulator, adjust
56117-4 Air drier, overhaul 1
56117-4 Air drier, overhaul
56125-3 Air drier insert, replace
56126-2 Air drier, drier insert, replace 1
56126-2 Air drier, drier insert, replace
56134-2 Air-drier preheating element, replace
56135-2 Solenoid valve, air drier, replace
56142-2 Pressure regulator, replace
56152-4 Compressor piston rings, replace
56153-5 Compressor, check and wear measurement
56171-4 Compressor, overhaul
56173-4 Pressure governor, overhaul 2
56173-4 Pressure governor, overhaul
56316-2 Relay valve, overhaul
56320-4 Pressure limiter valve, overhaul
56336-2 Regulating valve, overhaul
56357-2 Quick release valve (front), overhaul
56364-4 Four circuit protection valve, overhaul
56371-4 Control lever parking brake, overhaul
56372-4 Bogie lift valve, overhaul
56373-4 Footbrake valve, overhaul
57106-4 Trailer brake control, overhaul
61103-3 Steering knuckle, overhaul (one) 1
61103-3 Steering knuckle, overhaul (one)
64154-2 Steering column, replace
64252-2 Pressure point, steering gear, check and adjust 1
64252-2 Pressure point, steering gear, check and adjust
64254-2 Unloading mechanism, check and adjust 1
64254-2 Unloading mechanism, check and adjust
64305-5 Pitman arm, replace
64313-2 Ball joint, link rod and track rod, axial play, check
64512-4 Power steering pump, overhaul
65212-2 Bushings, reaction rod, replace (one side)
65234-2 V-stay rear, overhaul
65271-5 V-rod, outer ball joint, overhaul
65273-5 V-rod, centre joint, overhaul 1
65273-5 V-rod, centre joint, overhaul
65275-4 Reaction rod, overhaul
65516-4 Spring cradle, overhaul
65525-3 Shaft, spring cradle, replace 1
65525-3 Shaft, spring cradle, replace 2
65525-3 Shaft, spring cradle, replace
65556-2 Rear axles, check and adjust (parallelism)
65558-2 Bogie distance, check, measure and adjust
65570-1 Spring cradle, remove 1
65570-1 Spring cradle, remove
65572-1 Spring cradle, install 1
65572-1 Spring cradle, install
72508-2 Front anchorage, reaction rod, replace
72510-2 Bushings, front reaction rod, replace (one side)
72514-2 Level valve, front axle, setting
72515-2 Level valve, non-return valve and control valve, replace
72570-1 Cross member front, remove
72571-4 Cross stay front, overhaul
72572-1 Cross stay front, install
72602-2 Air bellows, drive axle, replace
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
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)
77343-3 Wheelstud, replace
77363-2 Rear wheel bearing and seal, replace 1
77363-2 Rear wheel bearing and seal, replace 2
77363-2 Rear wheel bearing and seal, replace
77365-3 Front wheel hub, remove
81820-2 Cab shock absorber rear, replace (one)
81870-1 Cab, remove
81872-1 Cab, install 1
81872-1 Cab, install
82130-2 Bonnet, remove-install
82540-2 Front mudguard, rear, replace (two sides)
83131-2 Door stop, replace
83138-2 Door hinges, adjust (one door)
83145-2 Door guide, adjust (one)
83404-2 Door handle outside, replace 1
83404-2 Door handle outside, replace
83414-2 Door lock, replace (one side)
83505-2 Window winder, replace 1
83505-2 Window winder, replace 2
83505-2 Window winder, replace 3
83505-2 Window winder, replace
83610-2 Roof hatch, replace
83613-2 Roof hatch springs, replace (all) 1
83613-2 Roof hatch springs, replace (all)
84150-2 Reflector, replace
84232-2 Decor stripes, new install (complete kit) 1
84232-2 Decor stripes, new install (complete kit)
84302-2 Windscreen, replace 1
84302-2 Windscreen, replace
84406-2 Door window, replace 1
84406-2 Door window, replace
84416-2 Ventilation window, replace 1
84416-2 Ventilation window, replace
85150-1 Door upholstery, remove 1
85150-1 Door upholstery, remove
85151-1 Door upholstery, install 1
85151-1 Door upholstery, install
85226-1 Driver’s seat, remove
85227-1 Driver’s seat, install 1
85227-1 Driver’s seat, install
85228-4 Driver’s seat shock absorber, replace
85278-2 Seat height level control valve, replace 1
85278-2 Seat height level control valve, replace
85505-1 Headlining, install 1
85505-1 Headlining, install
85507-1 Headlining, remove 1
85507-1 Headlining, remove
86103-2 Bumper, replace 1
86103-2 Bumper, replace
87010-1 Air conditioning system, remove
87012-1 Air conditioning system, install 1
87012-1 Air conditioning system, install
87402-2 Evaporator, replace
87404-2 AC compressor, replace
87408-2 Condenser, replace
87410-2 Receiver drier, replace
87412-2 Thermostat, replace
88408-2 Seat belt, replace (one) 1
88408-2 Seat belt, replace (one)
89110-2 Sun visor complete, replace 1
89110-2 Sun visor complete, replace
89114-2 Wind deflector, new install
Abbreviations
Actions regarding turbo failure
Additional procedures, basic and annual service
Adjusting the differential lock indication
Air bellows, driven axle, check
Air compressor
Air conditioning compressor
Air filter handling
Air suspension, pneumatic components
Alternator 1
Alternator 2
Alternator, disassembly
Alternator, installation
Alternator
Annual service, general
Anti-roll bar, rear
Axial play
Balancing the propeller shaft 1
Balancing the propeller shaft 2
Balancing the propeller shaft 3
Balancing the propeller shaft
Base engine (long block)
Basic housing
Basic information
Battery analyser 7200 user manual
Battery analyzer, 88890075 EXP, user manual
Battery charging
Battery troubleshooting
Battery, warranty claim handling, additional information
Battery
Bogie lift 1
Bogie lift
Brake cylinder
Cab 1
Cab removal
Cab suspension
Cab
Cables and connectors, fault tracing
Camshaft wear, check 1
Charge air cooler
Chassis lubrication
Check of high pressure monitor
Check, wear in cam housing
Checking the bogie lift and bogie press functions
Checks in the cab 1
Checks in the cab
Checks under the vehicle
Chemical products catalogue
Cleanliness in the clutch system
Clutch kit
Clutch linkage
Clutch plate, marking
Clutch specs
Clutch, check and replacement of components
Clutch
Collector ring, replacement
Compressed air components
Compressed-air tank
Compressor magnetic clutch, assembly
Compressor magnetic clutch, disassemble
Compressor
Control system components
Control unit, ABS
Control unit, engine
Control unit, immobilizer
Coolant pump
Cooling system
Core handling instructions
Crank mechanism
Crankshaft wear, check
Crankshaft
Cylinder head, check
Cylinder head
Diaphragm spring
Diff. lock
Differential carrier, exploded view
Differential carrier, section view
Differential carrier
Disc clutch
Doorstops
Double disc clutch
Drive plate
Dryer-receiver
Dual draw dual return fuel system troubleshooting
Engine 1
Engine compartment
Engine cover
Engine
Engines TD70, TD100, TD120 Steering gear Z8046 Front axle load FAT7.5
External checks 1
External checks
Failure diagnosis
Feeding pressure
Final drive specs
Final drive
Foot and hand controls
Front air suspension, components
Front differential – EV87
Front end, steering
Fuel system and used lubricant oil analysis, fault tracing
Fuel system
Gear control unit
Gearbox
General cab
General EV87
General
Hub reduction, checking the oil level and changing the oil
Hub reduction, exploded view 1
Hub reduction, exploded view 2
Hub reduction, exploded view
Hub reduction, overhaul (one side)
Hub reduction, section view
Hub reduction
Hub, rear
Hydraulic pump, service
Hydraulic system, fault tracing
Hydraulic system, general
Illustration A
Index
Injection pump
Injector rocker arm
Injector
Installation instructions, accessories
Intake and exhaust system
Level control
Lubricating and oil system
Lubrication, oil changes, fluid checks BASIC SERVICE
Lubrication, oil changes, fluid checks
Main bearing cap, replacement
Malfunction, probable causes and recommended action ALTERNATOR
Malfunctions, causes and remedial actions
Malfunctions, probable causes and procedures
Manual gearbox, warranty claim handling, additional information
MID 130 Transmission control unit, fault codes
Modification of cable harness for new brake contacts or horn
Oil and fuel consumption, follow-up
Oil cooler pipes sealing
Other special equipment
Outside sun-visor
Pedal play
Performance curves
Pipes, hoses and fittings
Position diagram, ABS NL10, NL12
Power steering gear, exploded view 2
Power steering gear, exploded view
Power steering pumps, exploded view
Power take-off 1
Power take-off specs
Power take-off
Press forces
Pressure limiting valve (pos 51)
Pressure plate
Preventive maintenance intervals
Propeller shaft descr
Propeller shaft
Pulling clutch, double disc
Pulling clutch, single disc
Push rod wear, check
R3 – Group 030
R3 – Group 561
R3 – Group 593
R3 – Group 642
R3 – Group 650
Radiator grille
Radiator
Reaar axle Specifications
Ready-reference, fault codes
Rear axle specs
Rear axle, general
Rear differential ­ EV80B-81B
Release bearing
Replacing output shaft bearing 1
Replacing output shaft bearing
Retroactive fitting of the corrugated plastic hose
Roof hatch
Safety rules
Separate regulator, test
Set of Test pins
Short block
Short stroke synchronization
Single disc clutch
Spacer sleeve
Special tools
Speed sensor with O-ring
Speedometer adapter gear, reduction ratio calculation
Spring cradle and stay
Spring cradle, remove 1
Standard tightening torques
Starter motor
Steering gear without intermediate cover, bearings and seals, replacing
Steering gear
Steering knuckle, exploded view
Steering wheel, steering shaft and steering shaft adjustment
Straps
Symbol index
Syncronizer
Tachograph speedometer, calibration
Tachograph]
Test instrument for checking speed limiter, range inhibitor, cruise control and the tachograph’s speedometer
The ESS function
Thermostat controlled fan
Tightening torques and patterns
Tightening torques clutch
Tightening torques compressor
Tightening torques rear
Torque rod
Towing information
Trailer brake circuit N, NL
Transfer gear, 1
Transfer gear,
Turbocharger
Tyre and inner tube
Unit injector
Unloading mechanism
Valve mechanism]
Valve plate, replacement
Valve seats, installation
Valve springs
Valves, inspection
Vehicle Identification Number VIN 1
Vehicle Identification Number VIN
Visual inspection
Voltage regulator
Volvo service program
VSP program
VSP
V-stay, axial play, check
V-stay, fitting
V-stay, reaction rod rear end
V-stay, removing (all types)
Washing, polishing and waxing, cab
Wearing tolerance
Wheel brake
Wheel installation
Wheel

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