Volvo VM Truck Service and Repair Manual PDF

Volvo VM Truck Service and Repair Manual PDF

Size: 1221.14 MB
Language: English
Make: Volvo
Machine: Truck
Document: Service and Repair Manual
Model: Volvo VM
Page: 24302 Pages

Detail Contents:
Bulletins – Information Index
Bulletins

• Adapter 62 pin 9998699
  Adapter 9813194
  Adapter 9990163
  Adapter 9998596
  Adapter 88800081
  Adjusting tool 9990239
  Antenna breakout box 9990135-1
  Antenna breakout box 9990135-2
  Assembly tool 88800154
  Base 88800099
  Battery analyser 88890075
  Brake cylinder repair device
  Connector 9996683
  Counterhold 88800092
  Densimeter 9985011
  Device 88800032
  Device 88800048
  Drift 9990057
  Drift 88800072
  Drift 88800073
  Drift 88800074
  Drift 88800075
  Drift 88800080
  Drift 88800096
  Drift 88800100
  Drift 88800101
  Drift 88800106
  Drift 88800107
  Drift 88800354
  Expander 88800095
  Extension 88800098
  Fixture 9990085
  Fixture 88800088
  Fixture 88800089
  General on Tech Tool
  Guide 88800077
  Guide 88800078
  Guide 88800079
  Guide 88800091-1
  Guide 88800091-2
  Guide 88800105
  Hose connection 88800082
  New board system and laminate
  Nipple 88800093
  Nut 88800087
  Piston ring compressor 88800039
  Plate 88800229
  Puller 9990060
  Puller 9990065
  Puller 9990067
  Puller 88800057
  R3 – Group 0800
  Socket 9990215
  Spacer 88800090
  Special Tool General information
  Special Tools, changes
  Spindle 88800446
  Wrench 9990054
  Yoke 9990064

Description, Design and Function Index
Description, Design and Function

• Abbreviations
  AdBlue information
  Alternator1
  Alternator2
  Alternator3
  Analysis of engine oil
  Battery1
  Battery2
  Brake fluid
  Burglar alarm
  Consumables
  Coolant
  Cooling system1
  Cooling system2
  Cooling system3
  Disassembly instructions, complete vehicle
  Driver’s actions and driving habits
  Driving power and fuel consumption
  Emissions aftertreatment system (EATS)
  Engine control system
  Engine oil
  Engine1
  Fuel system1
  Fuel system2
  Fuel tank, connections and lines
  General quality requirements
  General
  Grease
  Handling lubricants
  Immobilizer
  Instrument, system description
  Introduction
  Lubricants, fluids and oil analysis
  Lubrication and oil system1
  Lubrication and oil system2
  Maintenance-free battery
  Oils
  Pipes, hoses and fittings
  Pneumatic quick fitting system
  R3 – Group 0
  R3 – Group 21
  R3 – Group 070
  Recommendations for Volvo Trucks
  SCR related Fault Codes
  Storage
  Tachograph
  Transmission oil
  Updating VDA1
  Updating VDA2
  Vehicle Identification Number VIN1
  Vehicle Identification Number VIN2
  VIN Code
  Viscosity
  Volvo Standard Time

Diagnostics Index
Diagnostics

• 17012-3 Fault codes, reading
  28108-3 Engine control unit, check1
  28108-3 Engine control unit, check2
  28108-3 Engine control unit, check3
  28320-3 MID 128 SID 22 Engine speed sensor, check1
  28320-3 MID 128 SID 22 Engine speed sensor, check2
  28413-3 MID 128 PSID 53 Monitoring of pressure relief valve, check
  28428-3 MID 128 SID 78 Fuel priming pump, check1
  28428-3 MID 128 SID 78 Fuel priming pump, check2
  28432-3 MID 128 SID 21 Engine position timing sensor, check1
  28432-3 MID 128 SID 21 Engine position timing sensor, check2
  28450-3 MID 128 PID 45 Preheater relay, check1
  28450-3 MID 128 PID 45 Preheater relay, check2
  28453-3 MID 128 PID 91 Accelerator pedal position, check1
  28453-3 MID 128 PID 91 Accelerator pedal position, check2
  28455-3 MID 128 PID 100 Engine oil pressure, check1
  28455-3 MID 128 PID 100 Engine oil pressure, check2
  28456-3 MID 128 PID 102 Boost pressure, check1
  28456-3 MID 128 PID 102 Boost pressure, check2
  28457-3 MID 128 PID 105 Boost air temperature, check1
  28457-3 MID 128 PID 105 Boost air temperature, check2
  28460-3 MID 128 PID 110 Engine coolant temperature, check1
  28460-3 MID 128 PID 110 Engine coolant temperature, check2
  28462-3 MID 128 PID 158 Battery voltage, check1
  28462-3 MID 128 PID 158 Battery voltage, check2
  28465-3 MID 128 PID 175 Engine oil temperature, check1
  28465-3 MID 128 PID 175 Engine oil temperature, check2
  28472-3 MID 128 SID 1,2,3,4,5,6 Unit injector, check1
  28472-3 MID 128 SID 1,2,3,4,5,6 Unit injector, check2
  28484-3 MID 128 PSID 50 Fuel pressure monitoring (MPROP), check
  28503-3 MID 128 PID 164 Injection control pressure, check1
  28503-3 MID 128 PID 164 Injection control pressure, check2
  Alternator, fault tracing
  Alternator1
  Alternator2
  Battery troubleshooting
  Fuel system and used lubricant oil analysis, fault tracing
  General information
  Loss of power
  Low power output, fault tracing
  MID 128 Engine control unit, fault codes
  Starter motor troubleshooting
  Windshield wiper system fault tracing

Diagrams

• Component complete list
  Pneumatic diagram for the air supply
  Pneumatic diagram for the bogie lift
  Pneumatic diagram for the trailer brake
  Pneumatic diagram of the cab, TRBRAKE
  Pneumatic diagram of the cab, UTRBRAKE
  Pneumatic diagram of the front of the vehicle, TRBRAKE
  Pneumatic diagram of the front of the vehicle, UTRBRAKE
  Pneumatic diagram of the front wheels, TRBRAKE, ABS-WHL
  Pneumatic diagram of the front wheels, TRBRAKE
  Pneumatic diagram of the front wheels, UTRBRAKE, ABS-WHL
  Pneumatic diagram of the front wheels, UTRBRAKE
  Pressure sensors for the pneumatic system

Forms Index
Forms

• Battery, warranty claim handling, additional information
  Charge air cooler, additional information claim handling
  Check card storage maintenance
  Control unit, warranty handling, protocol
  Cylinder liner height
  Manual gearbox, warranty claim handling, additional information
  Oil and fuel consumption, follow-up
  Radiator, warranty claim handling, additional information

Repair Index
Repair Manual

• Bulletins – Information Index
  Bulletins
  Description, Design and Function 1
  Description, Design and Function Index
  Diagnostics 1
  Diagnostics Index
  Diagrams 1
  Forms 1
  Forms Index
  Repair 1
  Repair Index
  Service and Maintenance 1
  Specifications 1

Repair

• 21002-2 Cylinder compression test1
  21002-2 Cylinder compression test2
  21002-2 Cylinder compression test3
  21002-2 Cylinder compression test4
  21035-4 Engine parts, transferring1
  21035-4 Engine parts, transferring2
  21038-5 Engine, install and remove from overhaul stand1
  21038-5 Engine, install and remove from overhaul stand2
  21038-5 Engine, install and remove from overhaul stand3
  21070-1 Engine, remove1
  21070-1 Engine, remove2
  21070-1 Engine, remove3
  21070-1 Engine, remove4
  21070-1 Engine, remove5
  21072-1 Engine, install1
  21072-1 Engine, install2
  21072-1 Engine, install3
  21072-1 Engine, install4
  21072-1 Engine, install5
  21105-5 Valve seat, replace (one)
  21126-2 Cylinder head, replace1
  21126-2 Cylinder head, replace2
  21126-2 Cylinder head, replace3
  21126-2 Cylinder head, replace4
  21171-4 Cylinder head, pressure test (first)
  21191-5 Coolant seal cylinder head, replace1
  21191-5 Coolant seal cylinder head, replace2
  21207-5 Threads in engine block, clean (one cylinder head)
  21233-3 Flywheel housing, replace1
  21233-3 Flywheel housing, replace2
  21233-3 Flywheel housing, replace3
  21233-3 Flywheel housing, replace4
  21235-3 Flywheel housing run-out, check1
  21235-3 Flywheel housing run-out, check2
  21235-3 Flywheel housing run-out, check3
  21307-3 Cylinder liner seat, milling (first)1
  21307-3 Cylinder liner seat, milling (first)2
  21357-3 Piston and liner, replace (one)1
  21357-3 Piston and liner, replace (one)2
  21357-3 Piston and liner, replace (one)3
  21406-3 Valve stem seals, replace1
  21406-3 Valve stem seals, replace2
  21412-2 Valves, adjust1
  21412-2 Valves, adjust2
  21412-2 Valves, adjust3
  21412-2 Valves, adjust4
  21415-5 Valve guides, replace (one cylinder head)1
  21415-5 Valve guides, replace (one cylinder head)2
  21416-2 Valve stem seals, replace1
  21416-2 Valve stem seals, replace2
  21416-2 Valve stem seals, replace3
  21428-4 Rocker arm shaft, replace1
  21428-4 Rocker arm shaft, replace2
  21454-3 Valve tappets, replace (all)1
  21454-3 Valve tappets, replace (all)2
  21454-3 Valve tappets, replace (all)3
  21454-3 Valve tappets, replace (all)4
  21502-2 Gaskets, timing gear cover, replace
  21517-3 Sealing ring, timing gear cover, replace1
  21517-3 Sealing ring, timing gear cover, replace2
  21517-3 Sealing ring, timing gear cover, replace3
  21522-2 Camshaft, replace1
  21522-2 Camshaft, replace2
  21531-3 Timing gears, replace (all)1
  21531-3 Timing gears, replace (all)2
  21531-3 Timing gears, replace (all)3
  21607-3 Flywheel bearing, replace
  21611-3 Connecting rod bearings, replace (all)
  21612-2 Crankshaft drive belt pulley, replace
  21621-3 Flywheel, replace1
  21621-3 Flywheel, replace2
  21631-3 Flywheel, check1
  21631-3 Flywheel, check2
  21635-5 Connecting rod bushing, replace (each)
  21650-4 Crankshaft, replace1
  21650-4 Crankshaft, replace2
  21650-4 Crankshaft, replace3
  21667-3 Crankshaft seal, replace (rear)1
  21667-3 Crankshaft seal, replace (rear)2
  21667-3 Crankshaft seal, replace (rear)3
  21687-5 Flywheel ring gear, replace
  21867-2 Engine mounting bracket, replace (right rear)
  22112-2 Oil pump, replace1
  22112-2 Oil pump, replace2
  22112-2 Oil pump, replace3
  22112-2 Oil pump, replace4
  22121-2 Oil pressure, check1
  22121-2 Oil pressure, check2
  22121-2 Oil pressure, check3
  22121-2 Oil pressure, check4
  22207-3 Oil filter, engine, replace1
  22207-3 Oil filter, engine, replace2
  22207-3 Oil filter, engine, replace3
  22210-2 Oil filter, replace
  22212-2 Gasket oil filter housing, replace
  22320-2 Oil cooler, replace1
  22320-2 Oil cooler, replace2
  22320-2 Oil cooler, replace3
  22320-2 Oil cooler, replace4
  22323-3 Oil cooler, replace
  22325-5 Oil cooler, pressure test
  22341-2 Reduction valve, replace1
  22341-2 Reduction valve, replace2
  22341-2 Reduction valve, replace3
  22341-2 Reduction valve, replace4
  23003-3 Fuel system, bleeding1
  23003-3 Fuel system, bleeding2
  23003-3 Fuel system, bleeding3
  23302-2 Feed pump, replace1
  23302-2 Feed pump, replace2
  23302-2 Feed pump, replace3
  23303-2 Fuel filter, replace (one)1
  23303-2 Fuel filter, replace (one)2
  23303-2 Fuel filter, replace (one)3
  23303-2 Fuel filter, replace (one)4
  23307-3 Hand pump, feed pump, replace1
  23307-3 Hand pump, feed pump, replace2
  23307-3 Hand pump, feed pump, replace3
  23307-3 Hand pump, feed pump, replace4
  23312-2 Filter, water separator, replace1
  23312-2 Filter, water separator, replace4
  23312-2Filter, water separator, replace2
  23312-2Filter, water separator, replace3
  23314-2 Water separator, water draining1
  23347-2KUV valve, replace
  23350-2 Pressure limiting valve, replace1
  23350-2 Pressure limiting valve, replace2
  23351-2 Pressure sensor, replace1
  23351-2 Pressure sensor, replace2
  23378-2 Fuel feed pressure, check
  23414-3 Filter for fuel tank ventilation, replace
  23422-2 Fuel tank, clean
  23601-2 Dosage valve, replace1
  23601-2 Dosage valve, replace2
  23601-2 Dosage valve, replace3
  23617-2 Injection pump, setting with instrument
  23622-2 Injection pump, setting on engine
  23670-1 Injection pump, remove
  23672-1 Injection pump, install
  23702-2 Injectors, replace (all)
  23704-2 Injector, replace (one)1
  23704-2 Injector, replace (one)2
  23704-2 Injector, replace (one)3
  23717-2 Pressure pipe, replace1
  23717-2 Pressure pipe, replace2
  23717-2 Pressure pipe, replace3
  23821-2 Engine control unit, replace
  25102-2 Gaskets, intake manifold, replace1
  25102-2 Gaskets, intake manifold, replace2
  25102-2 Gaskets, intake manifold, replace3
  25102-2 Gaskets, intake manifold, replace4
  25104-2 Gaskets, exhaust manifold, replace1
  25104-2 Gaskets, exhaust manifold, replace2
  25104-2 Gaskets, exhaust manifold, replace3
  25104-2 Gaskets, exhaust manifold, replace4
  25104-2 Gaskets, exhaust manifold, replace5
  25222-2 Exhaust system complete, replace1
  25222-2 Exhaust system complete, replace2
  25222-2 Exhaust system complete, replace3
  25222-2 Exhaust system complete, replace4
  25222-2 Exhaust system complete, replace5
  25308-2 Control rods, exhaust brake, replace1
  25308-2 Control rods, exhaust brake, replace2
  25308-2 Control rods, exhaust brake, replace3
  25501-3 Waste gate activation, test
  25510-2 Boost pressure measuring, with manometer1
  25510-2 Boost pressure measuring, with manometer2
  25510-2 Boost pressure measuring, with manometer3
  25510-2 Boost pressure measuring, with manometer4
  25518-2 Engine turbocharger, replace1
  25518-2 Engine turbocharger, replace2
  25518-2 Engine turbocharger, replace3
  25518-2 Engine turbocharger, replace4
  25518-2 Engine turbocharger, replace5
  25603-3 Pressure drop indicator, air cleaner, replace
  25624-2 Filter insert, air cleaner, replace1
  25624-2 Filter insert, air cleaner, replace2
  25701-2 Crankcase ventilation, oil deflector, new install
  25807-2Pump unit, replace1
  25807-2Pump unit, replace2
  25811-2Dosage unit, replace1
  25811-2Dosage unit, replace2
  25811-2Dosage unit, replace3
  25811-2Dosage unit, replace4
  25811-2Dosage unit, replace5
  25815-2Exhaust temperature sensor, replace
  25820-4 SCR catalytic converter, check
  25823-2 Filter cover, AdBlue, replace
  25828-4 Combined tank unit, replace1
  25828-4 Combined tank unit, replace2
  25832-2 Aftertreatment diesel exhaust fluid (DEF) tank, filler neck insert, replace
  25832-2Aftertreatment diesel exhaust fluid (DEF) tank, filler neck insert, replace
  25837-2 NOX sensor, replace1
  25837-2NOX sensor, replace2
  25840-2Solenoid valve, heating AdBlue tank, replace
  25848-3 Strainer, replace
  25858-4 AdBlue tank, clean
  25862-2SCR catalytic muffler, replace1
  25862-2SCR catalytic muffler, replace2
  25862-2SCR catalytic muffler, replace3
  25883-3 Dosage unit, clean
  25885-4 Pressure sensor, replace
  25886-4 Temperature sensor, replace
  25921-2 Urea hoses, new install1
  25921-2 Urea hoses, new install2
  25921-2Urea hoses, new install3
  25938-4 Pump, replace
  26006-2 Cooling system, pressure test1
  26006-2 Cooling system, pressure test2
  26006-2 Cooling system, pressure test3
  26006-2 Cooling system, pressure test4
  26007-3 Cooling system, clean
  26010-2 Coolant, change1
  26010-2 Coolant, change2
  26010-2 Coolant, change3
  26010-2 Coolant, change4
  26011-2 Coolant type, replace
  26106-2 Radiator, external cleaning1
  26106-2 Radiator, external cleaning2
  26106-2 Radiator, external cleaning3
  26106-2 Radiator, external cleaning4
  26108-2 Radiator, replace1
  26108-2 Radiator, replace2
  26108-2 Radiator, replace3
  26108-2 Radiator, replace4
  26140-2 Coolant distributor pipe, replace1
  26140-2 Coolant distributor pipe, replace2
  26140-2 Coolant distributor pipe, replace3
  26140-2 Coolant distributor pipe, replace4
  26202-2 Coolant pump, replace1
  26202-2 Coolant pump, replace2
  26202-2 Coolant pump, replace3
  26202-2 Coolant pump, replace4
  26273-4 Thermostats, test1
  26273-4 Thermostats, test2
  26298-2 Thermostats, replace1
  26298-2 Thermostats, replace2
  26298-2 Thermostats, replace3
  26298-2 Thermostats, replace4
  26304-2 Drive belt, replace1
  26304-2 Drive belt, replace2
  26306-2 Thermostat fan, replace1
  26306-2 Thermostat fan, replace2
  26504-2 Charge air cooler, leakage test1
  26504-2 Charge air cooler, leakage test2
  26504-2 Charge air cooler, leakage test3
  26504-2 Charge air cooler, leakage test4
  27101-2 Pedal plate, replace
  27106-2 Sensor, accelerator pedal, replace
  27117-2Accelerator pedal, replace
  27318-2 Air cylinder, fuel shut-off, replace
  28421-2 Control unit, replace
  31102-2 Batteries, replace (all)
  31310-2Battery box, replace1
  31310-2Battery box, replace2
  31310-2Battery box, replace3
  32002-2 Charging test, in vehicle1
  32002-2 Charging test, in vehicle2
  32167-4 Alternator check, clean and test-run on bench
  33106-2Starter motor, replace
  33107-2Starter relay, replace
  33111-4 Starter solenoid, replace
  33112-4 Starter pinion, replace
  33113-4 Carbon brush, replace
  33170-1Starter motor, remove
  33172-1Starter motor, install
  35202-2 Headlights, adjust
  35268-2Headlamp, adjust (fog lamp)
  35310-2 Tail light complete, replace (One side)1
  35310-2 Tail light complete, replace (One side)2
  35641-2Fog lamp, replace
  36384-2 Wind screen wiper arm, replace
  36403-2 Cigarette lighter, replace
  36638-2 Immobilizer control unit, replace
  37101-1 Battery cable shoe, replace
  37204-2 Bracket, fuse and relay center, replace
  37301-2 Injectors cable harness, replace1
  37301-2 Injectors cable harness, replace2
  37301-2Injectors cable harness, replace3
  38168-2 Instrument complete, replace
  38306-2 Tachograph, replace
  38314-3 Tachograph, calibration
  38618-2 Fuel tank gauge sender, replace1
  38618-2 Fuel tank gauge sender, replace2
  38618-2 Fuel tank gauge sender, replace3
  38626-2 Fuel tank gauge sender, new install1
  38626-2 Fuel tank gauge sender, new install2
  38660-2 Impulse sender diff.lock indicator light, adjust
  38676-2 Clutch pedal microswitch, replace
  39703-2 Dynafleet, new install1
  39703-2 Dynafleet, new install2
  39716-2 Control unit, tracking system, replace1
  39716-2 Control unit, tracking system, replace2
  39723-3 Dynafleet, update1
  39723-3 Dynafleet, update2
  39731-2 Dynafleet Gateway, replace1
  39731-2 Dynafleet Gateway, replace2
  39741-2 Communication System SIM Card, Replacement1
  39741-2 Communication System SIM Card, Replacement2
  40151-2Electronic control unit (ECU) gear selector, replace
  40167-4 Pressure sensor, control housing, replace
  41103-3 Clutch plate, replace2
  41103-3 Clutch plate, replace3
  41103-3 Clutch plate, replace4
  41103-3Clutch plate, replace1
  41104-3 Clutch, wear check
  41183-2Valve assembly, clutch, replace
  41184-4 Position sensor, clutch, replace
  41202-2 Clutch pedal, adjust
  41204-3 Bearing clutch fork, replace1
  41204-3 Bearing clutch fork, replace2
  41204-3 Bearing clutch fork, replace3
  41204-3 Bearing clutch fork, replace4
  41283-5 Release bearing, pulling clutch replace1
  41283-5 Release bearing, pulling clutch replace2
  41314-2 Clutch cylinder, replace
  41320-3 Clutch cylinder, replace
  41336-2 Clutch servo, new install
  41340-2 Master cylinder clutch, replace
  41342-2 Clutch system, bleed
  41375-4 Clutch servo, overhaul1
  41375-4 Clutch servo, overhaul2
  43110-2 Bearing, output shaft, replace
  43111-2 Gear lever position, adjust
  43125-4 Split cylinder, overhaul
  43130-2 4339-03-02-01 Output shaft sealing ring, replace 1
  43130-2 Output shaft sealing ring, replace
  43130-2 Output shaft sealing ring, replace1
  43130-2 Output shaft sealing ring, replace2
  43130-2 Output shaft sealing ring, replace3
  43130-2 Output shaft sealing ring, replace4
  43130-2 Output shaft sealing ring, replace5
  43130-2 Output shaft sealing ring, replace6
  43131-4 Sealing ring input shaft, replace1
  43131-4 Sealing ring input shaft, replace2
  43131-4 Sealing ring input shaft, replace3
  43131-4 Sealing ring input shaft, replace4
  43131-4 Sealing ring input shaft, replace5
  43131-4 Sealing ring input shaft, replace6
  43131-4 Sealing ring input shaft, replace7
  43132-5 Brake, intermediate shaft, overhaul
  43133-1Oil filter housing, gearbox, remove1
  43133-1Oil filter housing, gearbox, remove2
  43133-1Oil filter housing, gearbox, remove3
  43133-1Oil filter housing, gearbox, remove4
  43134-1Oil filter housing, gearbox, install1
  43134-1Oil filter housing, gearbox, install2
  43134-1Oil filter housing, gearbox, install3
  43134-1Oil filter housing, gearbox, install4
  43141-5 Oil pump, overhaul
  43145-4 Sealing ring for output shaft, replace1
  43145-4 Sealing ring for output shaft, replace2
  43145-4 Sealing ring for output shaft, replace3
  43155-5 Range gear, remove
  43157-5 Range gear, install
  43158-1 Gearbox control unit, remove
  43164-2 Split cylinder, overhaul
  43166-1 Gearbox control unit, install
  43170-1 Gearbox, remove
  43172-1 Gearbox, install
  43173-5 Main shaft, overhaul1
  43173-5 Main shaft, overhaul2
  43173-5 Main shaft, overhaul3
  43173-5 Main shaft, overhaul4
  43173-5 Main shaft, overhaul5
  43173-5 Main shaft, overhaul6
  43174-1Range gear, remove1
  43174-1Range gear, remove2
  43174-1Range gear, remove3
  43174-1Range gear, remove4
  43174-1Range gear, remove5
  43175-5 Range gear, overhaul1
  43175-5 Range gear, overhaul2
  43175-5 Range gear, overhaul3
  43176-1Range gear, install1
  43176-1Range gear, install2
  43176-1Range gear, install3
  43181-5 Countershaft, overhaul1
  43181-5 Countershaft, overhaul2
  43181-5 Countershaft, overhaul3
  43181-5 Countershaft, overhaul4
  43181-5 Countershaft, overhaul5
  43181-5 Intermediate shaft, overhaul
  43185-5 Main shaft and countershaft, adjust
  43186-2 Cable gear selector, replace
  43187-4 Gearbox, disassemble-inspect-assemble1
  43187-4 Gearbox, disassemble-inspect-assemble2
  43187-4 Gearbox, disassemble-inspect-assemble4
  43187-4 Gearbox, disassemble-inspect-assemble5
  43187-4 Gearbox, disassemble-inspect-assemble6
  43187-4 Gearbox, disassemble-inspect-assemble7
  43195-5 Reverse shaft, overhaul
  43196-2 Combined cylinder, overhaul1
  43196-2 Combined cylinder, overhaul2
  43197-5 Input shaft, overhaul1
  43197-5 Input shaft, overhaul2
  43197-5 Input shaft, overhaul3
  43197-5 Input shaft, overhaul4
  43197-5 Input shaft, overhaul5
  43206-2 Gear lever, replace
  43206-2 Gear lever, replace1
  43206-2 Gear lever, replace2
  43208-2 Gear selector, replace
  43210-2 Auxiliary valve, replace
  43222-1 Control housing, remove
  43224-1 Control housing, install
  43231-4 Speed sensor and cable harness, replace
  43262-4 Brasspin selector fork, replace (all)
  43266-2 Range cylinder, overhaul
  43271-4 Upper cover, control housing, replace (complete)
  43274-1 Gearbox cover, remove
  43274-1 Gearbox cover, remove1
  43274-1 Gearbox cover, remove2
  43274-1 Gearbox cover, remove3
  43275-5 Gearbox cover, overhaul
  43275-5 Gearbox cover, overhaul1
  43275-5 Gearbox cover, overhaul2
  43276-1 Gearbox cover, install
  43276-1 Gearbox cover, install1
  43276-1 Gearbox cover, install2
  43276-1 Gearbox cover, install3
  43278-4 Control housing, overhaul1
  43278-4 Control housing, overhaul2
  43278-4 Control housing, overhaul3
  43278-4 Control housing, overhaul4
  43278-4 Control housing, overhaul5
  43284-3 Noise damper, gear lever, install
  43285-1 Gear shifting rod, overhaul
  43286-4 4325-04-04-01 Shift selector frame, overhaul
  43286-4 Shift selector frame, overhaul
  43288-2 Neutral position valve, replace
  43297-4 Intermediate lever, control housing, replace
  43297-4 Intermediate lever, control housing, replace3
  43610-4 Clutch housing, replace1
  43610-4 Clutch housing, replace2
  43610-4 Clutch housing, replace3
  45108-2 Propeller shaft rear, remove-install
  45110-2 Propeller shaft front, remove-install
  45110-2 Propeller shaft front, remove-install1
  45171-4 Universal joints, replace (each)
  45171-4 Universal joints, replace (each)1
  45171-4 Universal joints, replace (each)2
  45302-2 Intermediate bearing, replace
  46514-2 4658-03-02-01 Pinion sealing ring, replace 1
  46514-2 4658-03-02-01 Pinion sealing ring, replace
  46514-2 Pinion sealing ring, replace1
  46514-2 Pinion sealing ring, replace2
  46514-2 Pinion sealing ring, replace3
  46514-2 Pinion sealing ring, replace4
  46514-2 Pinion sealing ring, replace5
  46514-2 Pinion sealing ring, replace6
  46535-2 4659-04-02-01 Output shaft, overhaul
  46535-2 Output shaft, overhaul
  46540-2 Output shaft sealing ring, replace
  46540-2 Output shaft sealing ring, replace1
  46540-2 Output shaft sealing ring, replace2
  46544-2 Output shaft bearing, replace
  46544-2 Output shaft bearing, replace1
  46544-2 Output shaft bearing, replace2
  46570-1 4651-01-01-01 Differential carrier, remove 3
  46570-1 Differential carrier, remove
  46570-1 Differential carrier, remove1
  46570-1 Differential carrier, remove2
  46570-1 Differential carrier, remove3
  46570-1 Differential carrier, remove4
  46570-1 Differential carrier, remove5
  46571-4 4651-04-04-01 Differential carrier, overhaul 1
  46571-4 4651-04-04-01 Differential carrier, overhaul 2
  46571-4 4651-04-04-01 Differential carrier, overhaul
  46571-4 Differential carrier, overhaul
  46571-4 Differential carrier, overhaul1
  46571-4 Differential carrier, overhaul2
  46571-4 Differential carrier, overhaul3
  46571-4 Differential carrier, overhaul4
  46571-4 Differential carrier, overhaul5
  46571-4 Differential carrier, overhaul6
  46571-4 Differential carrier, overhaul7
  46571-4 Differential carrier, overhaul8
  46571-4 Differential carrier, overhaul9
  46572-1 4651-02-01-01 Differential carrier, install 2
  46572-1 Differential carrier, install
  46572-1 Differential carrier, install1
  46572-1 Differential carrier, install2
  46572-1 Differential carrier, install3
  46572-1 Differential carrier, install4
  46572-1 Differential carrier, install5
  46580-2 Shift mechanism, replace
  46582-2 Shift mechanism contact, adjust
  48108-2 Power take off (pto), replace
  48171-4 Power take-off, overhaul
  48273-3 Power take-off, overhaul
  50501-2 5931-03-02-01 Electronic control unit, changing 1
  50501-2 5931-03-02-01 Electronic control unit, changing
  51071-1 Brake linings, wear check (one axle)
  51085-4 Brake cylinder, overhaul (single diaphragm)
  51085-4 Brake cylinder, overhaul (single diaphragm)1
  51111-3 Front wheel brake, overhaul (one wheel)
  51117-3 Brake shoes, replace (one front wheel)
  51120-2 Brake cylinder, replace (front)
  51120-2 Brake cylinder, replace (front)1
  51121-3 Brake pads, replace (two front wheels)
  51133-3 Piston seal, replace
  51133-3 Piston seal, replace1
  51134-2 Brake drum, replace (one front wheel)
  51137-3 Brake caliper front wheel, replace
  51145-3 Brake disc, front wheel, replace
  51171-5 Guide sleeve seals, replace
  51173-2 Brake lining, replace (two front wheels)
  51175-5 Guide sleeves bushings and seals, replace
  51186-1 Brake cylinder, front wheel, remove
  51186-1 Brake cylinder, front wheel, remove1
  51188-1 Brake cylinder, install (front wheel)
  51195-3 5119-03-03-04 Bushings, seals and guide sleeves, replace
  51203-2 Brake linings drive axle, replace (two wheels)
  51218-2 Spring brake cylinder drive axle, replace
  51218-2 Spring brake cylinder drive axle, replace1
  51218-2 Spring brake cylinder drive axle, replace2
  51234-2 Brake drum, replace (one drive wheel)
  51303-2 Brake linings trailing axle, replace (two wheels)
  51318-2 Spring brake cylinder, trailing axle, replace
  51321-3 Brake pads, replace
  51351-3 Brakes trailing axle, overhaul (one wheel)
  51401-3 Brake cam, replace (one front wheel)
  51401-3 Brake cam, replace (one front wheel)1
  51421-2 Slack adjuster, replace (one front wheel)
  51421-2 Slack adjuster, replace (one front wheel)1
  51422-2 Slack adjuster, replace (one)
  51422-2 Slack adjuster, replace (one)1
  51423-2 Slack adjuster, replace (one)
  51441-3 Bushings and sealings, brake cam front wheel, replace (one wheel)
  51442-3 Bushings and sealings, brake cam driven wheel, replace (one wheel)
  51470-1 Slack adjuster, remove (front or trailing wheels)
  51472-1 Slack adjuster, install (front or trailing wheels)
  51472-1 Slack adjuster, install (front or trailing wheels)1
  51480-4 Slack adjuster, overhaul
  56111-2 Compressor, replace
  56111-2 Compressor, replace1
  56116-2 Air drier, replace
  56116-2 Air drier, replace1
  56126-2 Air drier, drier insert, replace
  56126-2 Air drier, drier insert, replace1
  56158-2 Non-return valve, check
  56170-1 Compressor, remove
  56171-4 Compressor, overhaul
  56172-1 Compressor, install
  56324-2 Parking brake hand control, replace
  56328-2 Load sensing valve, check and adjust
  56360-2 Quick release valve (rear), overhaul
  56364-4 Four circuit protection valve, overhaul
  56366-4 Relay valve, overhaul
  56374-4 Load-sensing valve, overhaul
  56391-2 Trailer brake valve, function check
  59326-3 5939-03-03-06 Wheel speed sensor, rear axle, replace (One side)
  59337-2 Solenoid valve, ABS, replace
  59338-3 5939-03-03-01 Wheel speed sensor, replace
  61002-2 Front end wear, check
  61002-2 Front end wear, check1
  61102-3 Steering knuckle, overhaul (one)
  61102-3 Steering knuckle, overhaul (one)1
  61103-3 Steering knuckle, overhaul (one)
  61114-2 6113-05-02-01 King pin journalling, adjust (one side)
  64028-2 Power steering, function check
  64104-2 Steering wheel, replace
  64154-2 Steering column, replace
  64164-2 Steering column lock, replace
  64282-1 Steering gear, remove
  64284-1 Steering gear, install
  64305-5 6437-03-05-01 Pitman arm, replace
  64312-2 Link rod, replace
  64370-1 Track rod, remove
  64372-1 Track rod, install
  64508-2 Power steering pump, replace
  64514-2 Oil and filter, power steering, replace
  64525-3 Oil filter, power steering, replace
  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, overhaul
  65275-4 Reaction rod, overhaul
  65275-4 Reaction rod, overhaul1
  65505-2 Lift bellows, replace
  65512-2 Spring cradle, overhaul
  65558-2 Bogie distance, check, measure and adjust
  65558-2 Bogie distance, check, measure and adjust1
  71130-2 Rear spring, front attachment, replace
  71131-2 Rear spring, central attachment, replace
  71132-2 Rear spring, rear attachment, replace
  71712-1 Underrun guard, remove
  71713-1 Underrun guard, install
  72004-2 Bellows height, check and adjust]
  72102-2 Front spring, replace (one)
  72102-2 Front spring, replace (one)1
  72107-3 Bushing, front spring rear anchorage, replace
  72107-3 Bushing, front spring rear anchorage, replace1
  72144-2 Front spring bushing, replace (one side)
  72218-2 Rear spring, replace (one)
  72234-2 Rear spring bushings, replace (two)
  72234-2 Rear spring bushings, replace (two)1
  72265-2 Rubber spring, replace (one)
  72281-1 Balance arm, remove
  72282-1 Balance arm, install
  72282-1 Balance arm, install1
  72283-4 Bushings, balance arm, replace
  72284-2 Rear spring, front stop, replace
  72285-2 Rear spring, rear stop, replace
  72614-2 Air spring member, rear, replace
  72680-2 Bushings, rear air bellows brackets, replace
  72828-2 Cable, mechanic levelling control, replace
  76106-2 Rear shock absorber bushings, replace
  76106-2 Rear shock absorber bushings, replace1
  76110-2 Front shock absorber bushings, replace
  76204-2 Rubber journal and bushing, anti roll bar front, replace
  76207-2 Rubber bearing anti roll bar rear, replace
  77312-2 Seal oil grease, rear wheel hub, replace (one side)
  77313-4 Seal, rear wheel hub UNIT, replace
  77343-3 Wheelstud, replace 1
  77343-3 Wheelstud, replace
  77363-2 Rear wheel bearing and seal, replace
  77378-2 Hub cap, replace
  77388-2 Wheel bearing and seal trailing axle, replace (one side)
  77388-2 Wheel bearing and seal trailing axle, replace (one side)1
  81501-1 Dashboard, remove
  81501-1 Dashboard, remove1
  81502-1 Dashboard, install
  81502-1 Dashboard, install1
  81801-2 Tilt cylinder, replace
  81802-2 Cab tilt pump, replace
  81810-2 Lock mechanism, replace 1
  81810-2 Lock mechanism, replace
  81822-2 Shock absorber front, replace (two sides)
  81826-2 Cab shock absorber rear, replace (two)
  81870-1 Cab, remove
  81872-1 Cab, install
  81876-2 8181-03-02-37 Cab bracket, replace (two sides)
  81876-2 Cab bracket, replace (two sides)
  81876-2 Cab bracket, replace (two sides)1
  81876-2 Cab bracket, replace (two sides)2
  81880-2 Cab front spring, replace (two sides)
  81880-2 Cab front spring, replace (two sides)1
  82142-2 Front hatch, replace
  82514-2 Front mudguard, front section, replace 1
  82514-2 Front mudguard, front section, replace
  83101-2 Door complete, replace
  83111-3 Remote control central locking, programming
  83134-2 Upper door hinges, replace
  83404-2 Door handle outside, replace
  84312-2 Rear window glass, replace
  84406-2 Door window, replace
  84601-2 Rear view mirror glass, replace
  84601-2 Rear view mirror glass, replace1
  84608-2 Electrical motor, rear view mirror, replace
  84611-2 Spot mirror glass, replace
  84612-2 Spot mirror assembly, replace
  84616-2 Rear view mirror, replace
  85150-1 Door upholstery, remove
  85151-1 Door upholstery, install
  85215-2 Backrest cushion, replace
  85217-2 Wire, height adjustment, replace
  85218-2 Seat suspension, replace
  85220-2 Vertical shock absorber, replace
  85221-2 Height limiter, replace
  85222-2 Wire, vertical shock absorber, replace
  85223-2 Control, tilt adjustment, replace
  85226-1 Driver’s seat, remove
  85227-1 Driver’s seat, install
  85231-4 Control, back rest and head restraint, replace
  85235-2 Backrest, replace
  85250-2 Backrest upholstery, replace
  85251-2 Seat cushion, replace
  85278-2 Seat height level control valve, replace
  85286-2 Motor and or drive cables for adjustment of seat angle, replace
  85288-2 Quick lowering valve, replace
  85292-2 Two way valve height adjustment, replace
  85294-2 Upholstery seat cushion, replace
  85295-2 Slide dog, replace
  85296-2 Cover seat frame, replace
  85305-2 Slide rails, replace
  85308-2 Control valve, replace
  85550-2 Roof upholstery, replace
  85550-2 Roof upholstery, replace1
  85580-2 Upholstery, replace (rear)
  85580-2 Upholstery, replace (rear)1
  85585-4 Covers, replace
  86108-2 Footstep, front bumper, replace
  86174-2 Front bumper corner, replace (one)
  87010-1 Air conditioning system, remove 1
  87010-1 Air conditioning system, remove
  87010-1 Air conditioning system, remove1
  87012-1 Air conditioning system, install
  87012-1 Air conditioning system, install1
  87012-1 Air conditioning system, install2
  87020-2 8700-18-02-04 Air conditioning system, new install
  87152-2 Heater control panel, replace
  87152-2 Heater control panel, replace1
  87305-2 Resistor, blower motor, replace
  87305-2 Resistor, blower motor, replace1
  87306-2 Air conditioning blower motor, replace
  87306-2 Air conditioning blower motor, replace1
  87402-2 Evaporator, replace
  87408-2 8746-03-02-01 Condenser, replace
  87410-2 Receiver drier, replace
  87412-2 Thermostat, replace 1
  87412-2 Thermostat, replace
  87436-2 Expansion valve, replace
  87480-2 Air conditioning condenser fan, replace
  87497-2 Air conditioning condenser fan motor, replace b1
  87497-2 Air conditioning condenser fan motor, replace
  ABS system, function check
  AC compressor, replace
  Adjusting unit assembly, driven axle, replace
  Air bellows, drive axle, replace
  Air conditioning
  Air drier, description, design and function
  Air drier, overhaul
  Air spring, replace
  Air suspension
  Automatically adjustable steering limiter, replace
  Automatically unloading mechanism steering gear, check
  Bogie lift
  Brake caliper rear wheel, replace
  Brake caliper, installing (one) side
  Brake caliper, remove (one) wheel
  Brake disc rear wheel, replace
  Brake disc, front wheel, replace
  Bushings, seals and guide sleeves, replace
  Cab tilt 1
  Cab tilt malfunction
  Cab tilt malfunction1
  Cab tilt
  Cab, tightening torques
  Cable repair
  Central locking system, signal description
  Compressor loading time, check
  Compressor, overhaul
  Compressor
  Control disk unit height adjustment, replace
  Door clearance
  Drive axle hub
  Driver’s seat shock absorber, replace
  Electric locks with immobilizer and alarm, design and function
  Footbrake valve, replace
  Four-circuit protection valve, function check
  Four-circuit protection valve, replace
  Frame rails and crossmembers
  Front hub, components
  Front leaf spring suspension
  Front leaf spring suspension1
  Front wheel hub Unit, replace (one side)
  Front wheel hub Unit, replace (one side)1
  Guide plate height adjustment, replace
  Levelling valve drive axle, replace (one)
  Load sensing valve, check and adjust
  Load sensing valve, replace
  Locking device, backrest, replace
  Maintenance instructions
  Maintenance program
  Malfunctions, causes and remedial actions
  Power steering pump
  Power steering, function check
  Power take off, new installation
  Quick release valve (front), overhaul
  Rear anti-roll bar rubber journal and bushing, replace, excl bushing frame attachment
  Rear leaf spring
  Rear wheel bearing, adjust (one wheel)
  Rear wheel brake, S-cam
  Replacing the remote control batteries
  Roof climate unit
  Seals, guiding sleeves, front axle, replace
  Seat
  Seat1
  Seats
  Service brake relay valve, replace
  Shift mechanism contact, adjust
  Sliding sleeves, wear measurement
  Split gear, jump out
  Spring cradle
  Spring suspension
  Steering knuckle
  Steering knuckle1
  Track rod, install
  Track rod, remove
  Trailer brake control valve, replace
  Trailer brake control, overhaul
  Trailer brake hand control, replace
  Tyre and inner tube
  Valves
  Welding requirements
  Wheel
  Windscreen, replace

Service and Maintenance

• 17102-2 Delivery service
  17210-2 Warranty service
  17232-2 Warranty service engine, new or exchange, after 4 weeks or maximum 10 000 km
  17241-2 Warranty service gearbox, new or exchange after 4 weeks or maximum 10 000 km
  17247-2 Warranty service rear or front final drive, after 4 weeks or maximum 10 000 km
  17504-2 Lubrication according to actual lubrication chart
  17523-3 Gearbox oil and filter, change 1
  17523-3 Gearbox oil and filter, change
  17527-3 Final drive oil, change
  17725-3 Driver’s service, optional
  17744-2 Basic service
  17746-2 Annual service
  17762-2 Air cooler, check
  56158-2 Non-return valve, check
  Air filter handling
  Chemical products catalogue
  Dupont process painting
  Fifth wheel, lubricate
  Preventive maintenance intervals
  Storage treatment of trucks
  Vehicle model VM
  Warranty service for spare parts and exchange parts
  Washing, polishing and waxing, cab

Specifications

• Air conditioning
  Air drier, specifications
  Alternator
  Alternator1
  Alternator2
  Battery
  Brake power
  BRAKE-M2 Front wheel brakes
  Cab tilt
  Cab, tightening torques
  Cable repair
  Camber, Castor, KPI
  Central locking system, signal description
  Clutch servo
  Clutch
  Compressor loading time
  Coolant operating temperature
  Diesel test standards 1
  Diesel test standards
  Disc brakes
  Door clearance
  Drive axle hub, specifications
  Engine 1
  Engine
  Expansion tank pressure
  Fifth wheel troubleshoot
  Fifth wheel, lubricate
  Fifth wheel
  Fifth wheel1
  Front leaf spring suspension
  Front leaf spring suspension1
  Front suspension, specifications
  Gearbox 1
  Gearbox, mechanical
  Gearbox
  Gearbox2
  General
  Global audio system
  Group 25 tightening torques
  Group 26 tightening torques
  Group 28 tightening torques
  Lubricating and oil system
  Parallelism
  Power steering pump
  Power steering pump1
  Power take-off
  Rear axle
  Rear axle1
  Rear axle2
  Rear axle3
  Rear axle4
  Rear axle5
  Seat
  Seat1
  Seat2
  Seat3
  Specifications index
  Standard tightening torques
  Starter motor
  Steering gear, specifications
  Steering knuckle, specifications
  Steering knuckle
  Suspension
  Suspension1
  System pressures
  Thermostatic valve
  Tightening torques
  Toe-in
  Trailing axle alignment
  Trailing axle mounting
  Turning angles
  Valves

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