Content

General information

• Vehicle identification
• Identification code
• Models complete set
• Lubricants and special fluids. Refueling volumes

Engine

• Engine view from different sides
• Datasheet
• Performance charts
• General characteristics
• Nominal sizes and fits of mating parts
• Troubleshooting
• Diagnostic devices
• Troubleshooting
• Tightening torques
• Diagrams of the sequence of tightening the bolts of fastening of the main engine components
• Tools and equipment
• Removal and engine installation
• Dismantling the engine at the stand
• Repair
• Assembling the engine at the stand
• Flywheel
• Lubrication system
• Cooling system
• Turbocharging system
• Turbocharger HOLSET HY55V
• Turbocharger HOLSET HX 50W
• Power system
• HIDROCAR power take-off on the gas distribution mechanism (optional)

Clutch

• Description
• Specifications
• Troubleshooting
• Tightening torques
• Tools and equipment
• Removing and installing clutch
• Checking
• Removing and installing bearing
• Clutch release
• Clutch release drive (for vehicles with gearboxes ZF 16 S 151/181/221 O.D.)
• Removing and installing the pedal unit
• Pedal unit
• Dismantlingcassembling the pedal unit
• Checking and adjusting the clutch pedal travel stops (for vehicles with gearboxes ZF 16 S 151/181/221 O.D.)
• Hydraulic clutch drive (for vehicles with gearboxes ZF 16 S 151/181/221 O.D.)
• Clutch slave cylinder for gearboxes ZF 16 S 151/181/221 O.D
• Bleeding hydraulic clutch actuator
• Clutch slave cylinder for gearbox EUROTRONIC 16 A S 2601 O.D.

Gearbox

• Gearboxes ZF 16 S 151/181/221 O.D
• Gearboxes ZF 16 S 151/181/221 O.D. with hydraulic retarder
• Gearbox EUROTRONIC 16 AS 2601 O.D
• Gearbox EUROTRONIC 16 AS 2601 O.D. with hydraulic retarder

Hydraulic retarder

• Location of the hydraulic retarder identification plate
• General information
• How it works
• Location of the main units of the retarder
• Removing and installing retarder on gearbox ZF S 151/181/221 O.D.
• Specifications
• Tightening torques
• Tools and equipment
• Troubleshooting
• Repair of the hydraulic retarder

Power take-off

• Description
• Specifications
• Tightening torques
• Tools and equipment
• Removal-installation of the power take-off
• Power take-off repair

Transfer cases and differentials

• Description of transfer case TC 1800 and TC 2200
• Specifications
• Version with power take-off (order number 391.392)
• Power take-off specifications
• Using the transfer case
• Transfer case differential
• Tightening torques
• Tools and equipment
• Lubrication system
• Removing and installing transfer case
• Disassembly of the transfer case at the stand
• Cleaning and checking parts
• Replacing the oil seals in the output shaft cover

Cardan shafts

• Specifications
• Troubleshooting
• Tightening torques
• Tools and equipment
• Removing and installing propeller shaft
• Cardan shaft repair
• Checking cardan shafts on a car

Bridges

• Troubleshooting
• Removing-installing rear axle
• Front axle 5985 / 2D (D1385)
• Middle bridges 452191 / 2D (R9274) 453291 / 2D (R9189)
• Middle bridge 452146 / 2D (R 9174)
• Rear axles 451391 / 2D (R 8284) 452191 / 2D (R 8274) 453291 / 2D (R 8298)
• Rear axle 452146 / 2D (R 8174)
• Twin bridges MERITOR RT 153E / 2D center axle RP 153E
• Rear axle RR 167E

Front and rear suspension

• Front and rear leaf springs
• Specifications
• Front shock absorbers
• Rear shock absorbers
• Pneumatic suspension
• Specifications
• The main components of the pneumatic system
• Troubleshooting
• Tightening torques
• Tools and equipment
• Removal-installation of front axle leaf springs
• Removal-installation of leaf springs of the intermediate (second) axle (8 ? 4 vehicles)
• Removal-installation of leaf springs of the rear axle (cars 4 ? 2 - 4 ? 4)
• Removal-installation of leaf springs of rear balance suspension (vehicles 6 ? 4 - 6 ? 6 - 8 ? 8)
• Rear balancer suspension (vehicles 6 ? 4 - 6 ? 6 - 8 ? 4 - 8 ? 8)
• Removal-installation of the reaction rod of the balance suspension of the rear axle
• Removalqinstallation of the reactive bar of the balancer suspension of the intermediate axle
• Removalqinstallation of the vq-shaped arm of the rear axle of cars with air suspension
• Replacing Throttle / V-Arm Pivot Pins
• Shock absorbers
• Anti-roll bars
• Anti-roll bar
• Front axle anti-roll bar
• Trailing axle anti-roll bar (8 ? 4 vehicles)
• Rear axle anti-roll bar
• Intermediate axle anti-roll bar (vehicles 6 ? 4 - 6 ? 6 - 8 ? 4 - 8 ? 8)

Wheels and tires

• Specifications
• Description
• Tools and equipment
• Troubleshooting
• Static wheel balancing
• Residual static imbalance correction
• Tire pressure
• Relationship between tire pressure and wheel behavior when driving

Steering

• Description
• Completion of vehicles with steering mechanisms
• Specifications
• Troubleshooting
• Tool
• Tightening torques
• Power steering gear
• Disassembly and assembly of the steering column
• Basic Operations

Pneumatic system - brakes

• Symbols on the schematic diagrams of pneumatic and hydraulic systems (auxiliary equipment and power units)
• Symbols on the schematic diagrams of pneumatic and hydraulic systems (valves)
• Symbols on the schematic diagrams of pneumatic and hydraulic systems (receivers and energy storage devices)
• Symbols on the schematic diagrams of pneumatic and hydraulic systems (transformers, cylinders and calipers)
• Symbols on the schematic diagrams of pneumatic and hydraulic systems (calipers and cylinders)
• Symbols on the schematic diagrams of pneumatic and hydraulic systems (half couplings and couplings)
• Symbols on the schematic diagrams of pneumatic and hydraulic systems (half couplings and couplings)
• Symbols on the schematic diagrams of pneumatic and hydraulic systems (control devices and switches)
• Symbols on the schematic diagrams of pneumatic and hydraulic systems (brakes)
• Tubes and fittings
• Braking system

Body and chassis

• Cab
• Tightening torques
• Tools and equipment
• Cab fixing
• Repair
• Replacing the front and rear cab suspension shock absorbers
• Removing and installing the front cab mount and its stabilizer
• Replacing the cab tilt cylinder
• Windshield replacement
• Replacing the sliding door glass
• Replacing the power window drive mechanism
• Replacing a fixed door glass
• Roof hatch replacement
• Driver's cab ventilation and heating
• Car frame
• Inspection and repair work
• Safety instructions

Scheduled maintenance

• Scheduled maintenance
• Additional work
• Inspection and / or maintenance work
• Location of inspection and / or maintenance points
• Location of inspection and / or maintenance points
• Inspection and / or maintenance work
• Maintenance M1
• Maintenance M2
• Maintenance M3
• Maintenance M4 (frequency is measured only in kilometers)
• Additional maintenance work
• Maintenance EP2
• EP3 maintenance
• Maintenance EP4
• Maintenance EP5