The second volume provides information on:

• - engine repair
• - gearbox repair
• - suspension repair

Content

Engine

• Accessory belt drive

9-liter engine

11-liter engine

12-liter engine

• Key features
• Replacing the engine
• Cylinder heads
• Cylinder block
• Flywheel and flywheel housing
• Crankcase ventilation and front crankshaft oil seal
• Connecting rod-piston group
• Flywheel
• Crankshaft
• Distribution mechanism
• Lubrication system
• Turbocharger
• Injection equipment and engine speed control

16-liter engine

• Technical data
• Removing and installing the engine
• Cylinder head
• Adjusting the unit injectors
• Cylinder head machining operations
• Replacing the valve guides
• Replacing the unit injector sleeves
• Cylinder block
• Measuring cylinder liner protrusion
• Undercutting the cylinder liner seat
• Replacing the crankshaft rear oil seal
• Removing the camshaft bearing
• Installing the camshaft bearings
• Flywheel housing removal
• Installing the flywheel housing
• Removing the front engine cover
• Installing the front engine cover
• Replacing the front crankshaft oil seal
• Removing the crankshaft oil seal cover
• Installing the crankshaft oil seal cover
• Replacing the plug in the cylinder block
• Crank mechanism
• Installing the piston
• Replacing the piston
• Checking the connecting rod
• Flywheel
• Crankshaft
• Camshaft drive gears
• Removing the idler gear
• Installing idler gear
• Replacing the idler gear bearing
• Removing the camshaft gears
• Installing the camshaft
• Removing the crankshaft drive gear
• Installing the crankshaft drive gear
• Removing and installing camshaft
• Checking the installation of the camshaft
• Fan drive
• Replacing the oil filter
• Replacing the oil cooler seal
• Heat exchanger installation
• Oil pump
• Exhaust manifold
• Turbocharger
• Engine mounts
• Attachment drive
• Engine cooling system

Fuel system

• Description of the fuel system with unit injectors and PDE and EDC MS6 control unit
• General information
• Fuel system hydraulic diagram
• Cyclic fuel supply and injection start moment
• Fuel system components
• Fuel system layout on engine
• Control unit cooler
• Fuel rail
• Fuel pressure regulator
• Unit injector
• Fuel filter
• Electronic fuel control system st EDC
• Elements of the EDC system located on the engine
• Elements of the EDC system located at the driver's workplace
• Fault code output
• Fault codes
• Fuel system performance tests
• Faults that do not cause trouble codes
• Interaction of EDC with other systems
• Repair of fuel system with unit injectors and PDE and EDC MS6 diesel engine electronic control system
• Unit injectors
• Removing the unit injector
• Removing the unit injector (16 liter engine, vehicle with T cab)
• disassembly of unit injectors
• Cleaning the unit injector
• Checking the unit injectors
• Adjusting the needle lift pressure
• Assembly of unit injectors
• Solenoid valve
• Installing the unit injector
• Installing the unit injector (16 liter engine, vehicle with T cab)
• Adjusting the pump injector
• Unit injector adjustment procedure
• Booster pump
• Fuel filter
• Bleeding the fuel system and measuring the pressure in the system
• Electronic diesel control (EDC) electrical cables
• EDC control unit
• Description of SCANIA HPI fuel system with EDC S6 control unit
• General information
• Fuel system hydraulic diagram
• Cyclic fuel supply and injection advance
• Fuel system components
• Pump-injector
• Electronic fuel control system EDC S6
• Elements of the EDC system located on the engine
• Elements of the EDC system located at the driver's workplace
• Cruise control system controls
• Fault indicator and fault codes output
• Fault codes
• Storing fault codes in the memory of the control unit
• Emergency operation
• Interaction of the EDC system with other systems
• Motor retarder
• Hydraulic retarder
• Pulse width modulated signals
• CAN bus
• Repair of Scania HPI fuel system with EDC S6 control unit
• General provisions
• Removing the unit injector
• Installing the unit injector
• Adjustment of clearances in the valve mechanism and closing force of pump-injectors
• Checking the pressure in the fuel system and the fuel supply
• Checking the tightness of the fuel system
• Replacing the fuel filter
• Installation
• Fuel rail, valve block and solenoid valves
• Fuel cut-off valve
• Fuel lines
• Electrical connections on the control unit

Gearboxes (GR801, GR900, GRS890, GRS900, GRS920, GRSH900, GRSO900)

• Datasheet
• Gearbox GR801
• Gearbox GR900
• Gearbox GRS900
• Gearbox GRS890
• Gearbox GRS920
• Gearbox GRSO900
• How it works
• Main gearbox
• Input shaft
• Axle of the idler reverse gear
• Secondary shaft
• Intermediate shaft
• Synchronizer
• Planetary demultiplier
• Shift housing cover
• Gearshift housing
• Demultiplier and Divider
• Divider blocking valve
• Inductive speed sensor with overspeed protection
• Shift Knob
• Lubrication system
• Gear shifting
• Technical data
• Repair
• Main gearbox
• Dismantling the gearbox
• Synchronizer
• Gearshift housing
• Checking the shift pins
• Separate assembly operations for GRS gearboxes
• Gearbox assembly
• Adjusting the bearing clearance
• Installing planetary gear
• Installing the gearshift housing and gearshift housing
• Specification
• Dismantling and installation of manual transmissions
• Gearbox with torque converter
• Cars with all-wheel drive transmission
• Transmission with automatic switching system "Opticruise"
• Gearbox without hydraulic retarder
• Dismantling gearboxes
• Draining coolant and oil from hydraulic retarder
• Technological engine mounts
• Disconnecting the clutch release
• Installation of gearboxes
• Preparing the clutch for gearbox installation
• Filling coolant and hydraulic retarder
• Tightening torques
• Transmission oil cooler
• Replacing the oil cooler for 11 and 12 liter engines
• Replacing the oil cooler for a 14 liter engine
• Replacing the oil cooler for a 16 liter engine
• Checking the tightness of the oil cooler
• Shafts of manual transmissions
• Dismantling the input shaft
• Input shaft assembly
• Disassembly of the output shaft
• Replacing the splitter gear bearing ring
• Output shaft assembly GRS / GRSO / GRSH
• Output shaft assembly GR801 / 900
• Intermediate shaft of gearbox GR801
• Intermediate shaft of the GR900 gearbox
• Intermediate shaft of the GRS gearbox
• Dismantling the intermediate shaft
• Assembling the intermediate shaft
• Tightening torques for screw connections
•  
• Consumables
• Transmission control actuator for P and R series vehicles
• Precautions
• General information
• Design differences
• General view of the control drive
• Shift lever assembly
• Gear shift drive
• Support bracket
• Check and adjust
• Adjustment parameter and tightening torques for threaded connections

Main gear

• Datasheet
• General provisions
• Bevel final drive
• Tooth contact pad
• Final drive ratio
• Bearings
• Middle and rear drive axles
• Cross-axle differential
• Center differential
• Differential lock mechanism
• How it works
• Lubrication system
• Repair manual
• General information
• Compliance with the requirements of cleanliness
• Security measures
• Disassembled main gear
• Adjusting the air-hydraulic pump to a given force
• Oil
• Replacing the universal joint yoke lip seal
• Dismantling and assembling the main gear
• Differential repair
• Drive gear repair
• Adjusting the lateral meshing play and bearing preload
• Differential lock mechanism
• Specification
• Specification of other main gears
• Exploded view of R780 final drive
• Exploded view of the main gear R560 / R660
• Disassembled RB660 main gear
• Disassembled RB662 main gear
• Exploded view RP832 / RBP832 final drive
• Exploded view RP730 / RP731 final drive
• Disassembled RBP730 / RBP731 main gear

Air compressors

• Compressor description
• Compressor repair

Suspension

• Vehicles with leaf springs
• Repair manual
• Cars with air suspension

Epilogue