Contents

Operation and maintenance manual

Typical data

Vehicle equipment

• Door control
• Seat adjustment
• Seat with pneumatic suspension
• Passenger seat (long cab)
• Seat belts
• Dashboards
• Traffic indicator recorder (Tachograph)
• Tachometer
• Combined appliance
• Warning buzzer
• Battery breaker
• Steering wheel lock
• Combo switch
• Headlight switch
• Beam range adjustment
• Steering wheel adjustment
• Window and mirror management
• Changeover valves
• Sun protection
• Heating and ventilation
• Shelves
• Bumper guard
• Opening the bonnet trim

Operation

• Preparing for the trip
• Air filter dirty
• Liquid level
• Seat belts
• Starting and stopping the engine
• Parking brake control
• Driving start and gear shifting
• Transmission type "Ecosplit" ("Disengagement") ZF16S
• Pneumatic electronic shift transmission
• Gearbox without electronic pneumatic shift
• Differential lock control
• Power take-off changeover
• Running in
• Run-in order
• Operation
• Brakes
• Parking
• Anti-lock system (ABS)
• Trailers and semi-trailers
• Dump truck use
• Auxiliary axis control
• Pneumatic shock absorbers
• Operation in winter conditions
• Auxiliary device "Startpilot"
• Driving

Fuels and lubricants

• Engine oils
• Coolant
• Diesel fuel

Care and prevention

Tiltable cab

Engine

• Specifications
• Oil and filter change
• Removing and installing valve bodies
• Setting valve clearance
• Flywheel teeth lubrication

Fuel system

• Cleaning the fuel tank
• Bleeding the fuel system

Cooling system

• Replacing the coolant

Clutch

Gearbox

• Checking the oil level and changing it
• Front axle
• Rear axle
• Cleaning the ventilation valve
• Oil level check and oil change

Steering

• Specifications

Wheels and tires

• Spare wheel location
• Wheel replacement

Braking system

• Adjusting the brakes
• Brake system diagrams and explanations

Chassis and body

• Lubrication
• Centralized lubrication system
• Car wash and care
• Car conservation measures
• Preparing a mothballed car for work
• Cab fixing

Electrical equipment

• Incandescent lamps overview
• Replacing incandescent bulbs
• Fuses
• Troubleshooting

Engine and fuel system

Clutch

Steering

• Braking system
• Electrical system
• Electronic-pneumatic gear shifting
• Fan
• Towing and starting towing

Repair manual

Engine

• General information
• Overview of complete sets
• Sectional view

Special tool

Specifications

• OM 441 engine
• OM 441 LA engine
• OM 442 engine
• Engine OM 442 A
• Engine OM 442 LA
• Engine OM 443
• Engine OM 443 LA
• Industrial motors 80/1269 / EEC
• DIN 6271
• OM 442 A engine (industrial engine)
• OM 442 LA engine (industrial engine)
• OM 444 A engine (industrial engine)
• OM 444 LA engine (industrial engine)

Tightening torques (kgm)

Repair of threaded holes using HELI-COIL inserts

• How to work
• Compression test
• Removing and installing cylinder head cover
• Removing and installing cylinder head
• Cylinder head mating surface treatment
• Removing and installing oil sump
• Timing gear housing cover seal
• Removing and installing timing gear housing
• Replacing the front crankshaft oil seal
• Oil seal replacement
• Replacing the crankshaft running ring
• Elimination of corrosion marks on the cylinder block mating surface
• Refinement of bore for liner in the cylinder block
• Measuring cylinder liner protrusion
• Removing, installing and sealing the cylinder liner
• Removing and installing oil separator
• Removing and installing torsional vibration damper or hub
• Replacing the crankshaft rear oil seal
• Flywheel running ring replacement
• Removing and installing the crankshaft, replacing bearings
• Crankshaft grinding
• Replacing the connecting rod bearings
• Installing connecting rod bearings
• Removing pistons
• Installation of pistons
• Replacing piston rings
• Flywheel removal and installation
• Flywheel machining
• Replacing the flywheel ring gear
• Flywheel Pilot Bearing Replacement
• Valve drive backlash adjustment
• Valve stroke check
• Replacing valve springs
• Installing valve stem seals
• Valve Guides
• Replacing valve seats
• Removing and installing valves
• Grinding valves
• Valve seat machining
• Replacing the valve rocker arms
• Checking engine camshaft timing
• Checking the axial clearance of the camshaft
• Removing and installing camshaft
• Replacing the camshaft bearings

Overview of high pressure fuel pumps

• Replacing the fuel filter
• Checking injectors
• Disassembly, cleaning and assembly of nozzles and sprayers
• Removing and installing injector
• Checking the fuel injection advance angle
• Removing and installing high pressure fuel pump
• Checking the turbocharger
• Removing and installing a turbocharger
• Disassembly and assembly of the turbocharger
• Replacing V-belts
• Disassembly and assembly of the air compressor
• Removing and installing intake manifold
• Removal and installation of the exhaust manifold
• Checking the engine brake adjustment
• Adjusting the engine brake
• Removal and installation of the generator
• Removing and installing starter
• Engine oil consumption measurement
• Removing and installing the filter element of the oil filter
• Oil pressure sensor replacement
• Removing and installing oil filter bypass valve
• Removal and installation of the overpressure valve
• Removing and installing oil nozzle
• Removing and installing oil pump
• Disassembly and assembly of the oil pump
• Removing and installing oil cooler
• Disassembly and assembly of the oil cooler
• Degreasing and descaling the cooling system
• Disassembly and assembly of the water pump
• Removing, installing and checking thermostats

Clutch

• 1948 car clutch
• Detailed characteristics
• Car clutch 1935.1944
• Detailed characteristics
• Practical advice
• Bleeding the clutch hydraulic circuit
• Clutch pedal play

Gearbox

• Gearbox G180-16 / 11.9 Electronic pneumatic drive (EPG / EPS)
• Gear lever
• Neutral contactor adjustment
• Clutch Pedal Travel Detector (SKU)
• Demonstration on the scoreboard
• Diagnostics
• Practical advice
• Shaft preparation
• Main crankcase installation
• Front cover (input relay)
• Output relay
• Oil pump
• Back cover
• Gearbox G4 / 155-16 / 14 (chassis 6x4 2629 and 2635)
• Practical advice
• Dismantling the gearbox
• Shaft preparation
• Main crankcase installation
• Front cover (input relay)
• Output relay
• Oil pump
• Back cover
• Gearbox GV4 / 110-6 / 9 (chassis 4x4 1929, 6x6 2629)
• Practical advice
• Dismantling the gearbox
• Removing the relay
• Shaft preparation
• Gearbox installation
• Input relay
• Main crankcase
• Clutch stop guide
• Main crankcase rear cover
• Installing the gear drive
• Gearbox VG 1400-3W
• Practical advice
• Gearbox
• Shaft preparation
• Pinion housing and ring gear holder
• Gearbox installation
• Side clearance adjustment
• Gearbox VG 2000-3W
• Practical advice
• Dismantling the gearbox
• Input shaft and satellites upper housing
• Idler gear
• Output shaft and inner casing of satellites
• Installing the gearbox
• Gear and input shaft
• Upper casing of satellites
• Actuator mounting
• Idler gear
• Secondary shaft
• Lower part of the satellite housing
• Installing the front cover
• Tachometer and oil pump drive box

Rear axle

• Detailed characteristics
• Dismantling and assembling the rear axle
• Dismantling the pinion
• Dismantling the differential
• Differential installation
• Pinion assembly
• Assembly of the mechanism
• Dismantling and installing differential lock
• Wheel hub reducers
• Wheel hub
• Removing and installing rear axle

Front axle

• Detailed characteristics
• Practical advice
• Installing the pivot shaft
• Hub assembly
• Front axle

Front axle (4X4 and 6X6)

• Detailed characteristics
• Practical advice
• Wheel hub
• Trunnion
• Cardan seal and bearings
• Parallelism adjustment

Suspension

• Air suspension
• Practical advice
• Checking the regulator (2.4) and gearbox (29.1)
• Suspension adjustment
• Leaf springs
• Practical advice
• Center pad
• Anti-roll bar
• Springs
• Shock absorbers
• Pulls

Steering

• Detailed characteristics
• Practical advice
• Emptying the control box
• Checking the oil level
• Checking and adjusting the wheel alignment line
• Steering shaft adjustment
• Checking the operation of the hydraulic servo system
• Checking the maximum pressure of the power steering pump
• Checking pump performance
• Checking the steering pressure
• Steering check (oil leak)
• Checking clearance and wear
• Checking and adjusting swing limits

Braking system

• Detailed characteristics
• Practical advice
• Drive shaft for brakes
• Replacing the ball bearings of the drive shaft bearings
• Parking brake
• Release of spring cylinders (emergency repair)
• Automatic pad wear compensation adjusters
• Braking corrector

Centralized lubrication system

• Technical data
• Checking and adjusting the fluid level
• Checking and setting working intervals
• Gear oil pump

Electrical equipment

• Checking and adjusting headlights

Wiring diagrams

• Wiring diagrams