The second volume provides information on repairs:

• - cooling systems
• - fuel system;
• - clutch and gearbox;
• - brake system.

Content

Cooling system

• General information
• Radiator
• Coolant bypass
• Circulation in the engine 12 l
• Circulation in the engine 14 l
• Expansion tank
• Level indicator
• Thermostat
• Coolant filter
• Cooling pump
• Cooling system maintenance
• Adding coolant
• High coolant temperature
• Low coolant temperature
• Coolant leak
• Cooling system cleaning - interior
• Radiator (P and R cabs with plastic bumper)
• Removing the radiator
• Installing a radiator
• Radiator (P and R cabs with metal bumpers)
• Removing the radiator
• Installing a radiator
• Radiator (T cab)
• Removing the radiator
• Radiator replacement
• Installing a radiator
• Expansion tank
• Pressure limiting valve
• Fan
• Withdrawal
• Installation
• Checking fan operation
• Thermostat
• Coolant filter
• Coolant pump
• Withdrawal
• Installation
• Inspection
• Pulley
• Oil seal
• Installation
• Checking the thermostat operation
• Belt drive

Fuel equipment

• Fuel filter
• Replacement
• Fuel filter with water separation
• Additional fuel filter with water separation
• Distribution tube
• Feed pump
• Measuring the pressure of the feed pump
• Single-acting feed pump
• Double-acting feed pump
• Bypass valve
• Fuel valve
• Injectors
• Injection pump
• Replacing the pump on DSC9 and 11 engines
• Replacing the pump on the DSC12 engine
• Replacing the pump on the DSC14 engine
• Injection adjustment on DSC 9, 11 and 12 engine
• Injection adjustment on the DSC 14 engine
• Overflow injection control
• Unit injectors
• Fuel system service
• Bleeding the fuel system
• Replacing the feed pump
• Replacing the wires of the unit injectors
• Replacing wires on a free panel
• Replacing the control unit
• Connecting special functions for the engine
• Fuel heater
• Fuel heater installation
• Heater connection diagrams
• All-speed regulator RQV
• Idling and maximum speed regulator RQ
• Smoke limiter
• Starting the engine with preheating
• Elements of the engine preheating system
• Troubleshooting
• Testing
• Preheat starting engine connection diagram

Clutch

• Removing the gearbox
• Replacing the clutch slave cylinder
• Checking the spring diaphragm
• Checking the pressure plate
• Installing the clutch
• Installing the gearbox
• Servo replacement
• Draining the hydraulic system
• Clutch K432 15, K432 16, K432 17, K432 18

Gearbox

• Withdrawal
• Installation

Gearbox GR801 / 900, GRS890 / 900

• Control scheme
• Overexcitation protection
• Neutral valve
• Isolation Valve, Divider Gear
• Control valve, separator / row
• Row wiring diagram, troubleshooting
• Checking the circuit of the solenoid valve in the control valve next
• Checking the engine speed sensor circuit
• Checking the E8 overexcitation protection device
• Power check
• Row switch test
• Divider wiring diagram, troubleshooting
• Power check
• Checking the separator switch
• Checking the circuit of the solenoid valve in the split control valve
• Checking the clutch switch
• Checking the circuit of the solenoid valve in the isolating valve
• Row air circuit, troubleshooting
• Neutral valve
• Row control valve
• Split isolation valve, air circuit GRS890 / 900
• Separation control valve
• Gearbox GR 900
• Lubrication system
• Gear shifting
• Transmission of torque in different gears in the main gearbox
• Power takeoff
• Synchronizers
• Cruise control, hall sensor, adjustment and replacement
• Replacing the longitudinal cylinder
• Replacing the side stroke cylinder
• Axial clearance
• Filling volumes
• Gearbox GR801

Torque booster KH 424 3

• Torque converter
• Torque boost
• Locking clutch

Braking system

• Air flow diagram
• Location of brake system components
• Complete diagram of air lines of SCANIA 4 series cars
• Explanation of designations on the diagram of air lines
• Front brake circuit
• Supply section supplying compressed air to the single wheel front axle
• Supply section that supplies air to the two front axles
• Executive part of the front brake circuit, front axle with single wheels
• Front contour diagram, front axle with single wheels
• Front contour diagram, two front axles
• Executive part, cars with two front axles
• Rear brake circuit
• Power supply
• Executive part, single rear axle with leaf spring or air suspension
• Executive part, bogie of additional (non-driving) rear axle. with air suspension and 4-channel ABS
• Executive part, bogie of additional rear axle. with leaf spring suspension and 4-channel ABS
• Executive part, double trolley. with leaf spring suspension and 4-channel ABS
• Executive part, bogie of additional rear axle and double bogie. with air suspension and 6-channel ABS
• Executive part, three-row trolley. with additional steering axle
• Rear brake circuit diagram, bogie of additional rear axle. with air suspension and 4-channel ABS
• Rear brake circuit diagram, single rear axle. with leaf spring or air suspension
• Rear brake circuit diagram, bogie of additional rear axle. with leaf spring suspension and 4-channel ABS
• Rear brake circuit diagram, double bogie. with leaf spring suspension and 4-channel ABS
• Rear brake circuit diagram, rear axle bogie and tandem bogie. with leaf spring suspension and 6-channel ABS
• Rear brake circuit diagram, three-axle bogie with air suspension. and an additional rear axle in front of the driving axle (wheel arrangement 8x2 / 4)
• Rear brake circuit diagram, three-axle bogie. with air suspension and an additional rear axle behind the driving axle (wheel arrangement 8x4 * 4)
• Parking brake circuit
• Compressed air supply
• Executive part
• Parking brake control procedure
• Secondary brake position
• Parking brake position
• Check position
• Trailer braking circuit
• Additional equipment outline
• Trailer outline diagram
• Parking brake circuit diagram

Compressed air supply system

• System components
• Compressor
• Air dryer
• Four-way safety valve
• Safety valve (safety)
• Bypass valve
• Compressor
• Withdrawal
• Dismantling the cylinder head
• Cylinder head cleaning and assembly
• Compressor troubleshooting
• Installation
• Air dryer
• Withdrawal
• Replacing the desiccant cartridge
• Valve body replacement
• Check valve replacement
• Air dryer installation
• Pressure relief test
• Bypass valve
• Disassembly
• Cleaning and checking
• Build
• Installation
• Specifications

Details of the front and rear brake circuit

• Service brake valve
• Pressure regulator valve (responsive to the weight of the machine load)
• Pressure regulating valve type I, for trucks with leaf spring suspension
• Pressure regulator valve type II, for trucks with air suspension
• Safety valve
• Booster valve
• Pressure gauge / indicator
• Service brake valve
• Pressure regulator valve for trucks with leaf spring suspension
• Pressure regulator valve for air suspension trucks
• Installing a pressure regulator valve
• Booster valve

Parking brake. Main nodes

• Manual directional valve
• Directional valves types I and II with test positions
• WABCO type I and III control valves
• Emergency braking
• Emergency braking / parking brake position
• Test position, type I control valve only
• Actuator position type II and IV directional valves (KNORR)
• Emergency braking with directional valves type II and IV, parking position with valve type II
• Type IV directional valve without test position
• Test position, only for type II control valve
• Manual control valve operation diagram
• Block valve
• Parking brake accelerator valve
• Pressure limiting valve
• Low pressure indicator
• Double check valve
• Quick release valve
• Disengaging the parking brake
• Applying the parking brake
• Components used to disengage the parking brake when using the second generation electronic air suspension control (ELC2)
• Back-up brake valve
• Removal and installation of main units

Symbols of elements of the brake system on the diagrams

• The principle of building a pneumatic circuit
• Compressed air lines
• Brake components

Components and parts of a wheel brake

• Service brake chambers
• How the service brake works
• Checking the service brake
• How the parking brake works
• Disengaging the parking brake
• Brake pad backlash adjuster
• Manual gap adjustment
• Automatic gap adjustment
• Brake drums
• Service brake chamber
• Removing the spring brake chamber from the truck
• Disconnecting the chamber spring assembly from the service brake assembly
• Assembling the spring chamber and service brake chamber assemblies
• Mechanism for manual clearance adjustment
• Removing from the truck
• Disassembly
• Cleaning and checking
• Installation on a truck
• Measuring the basic setting of the pusher
• Customization
• Mechanism for automatic clearance adjustment
• Measuring the basic setting of the pusher
• Removing from the truck
• Disassembly
• Cleaning and checking
• Build
• Setting the spring force
• Installing a slack adjuster on a truck
• Customization
• Removing the brake drum
• Removing the brake pads
• Brake cam rollers
• Brake pads and friction linings
• Brake drums
• Specifications

Disc brakes

• Removing wheels
• Disc brake related components
• Replacing brake pads
• Brake caliper
• Repair of brake calipers
• Replacing the pilot pins, bushings and seals
• Replacing the piston with oil seals
• Spring brake chamber
• Replacing the spring brake chamber
• Diaphragm replacement

ABS / TC system

• Friction
• Slipping
• Correlation between friction and skidding
• ABS system
• What happens while driving with the ABS system
• TS system
• ABS / TC system
• Braking control
• Engine management
• Operation of the vehicle system in off-road conditions (TC OFF ROAD)
• What happens during management
• Wheel sensor
• Control node design
• Control node subsystems
• ABS indicator lamps
• Indicator lamp of the vehicle system
• Control valve functions
• Solenoid valve function
• Double check valve function
• Accelerating valve on a tractor with an additional rear non-driving axle
• Installing the ABS system on other types of cars
• Block diagram of the ABS / TC system of a 4x2 truck

4 and 6 channel WABCO ABS / TC systems (D versions)

• Control unit
• Reading fault codes
• Troubleshooting
• Electrical connections for wheel diagonals
• Generating trouble codes
• Electrical diagram
• Component designation and resistance
• Wiring diagrams
• Layout of components
• 4-channel system diagrams
• 6-channel system diagrams

Braking system with EBS from BOSCH

• System diagram
• Troubleshooting
• Flashing codes
• Electrical components
• Electrical diagrams

Reduction of brake pressure in the chain of the front wheels

• Pressure relief valve 66a (V73)
• E41 control unit
• Signal lamp W31

Retarder brake (retarder)

• Hydraulic part
• Additional brake
• Oil accumulator
• Oil cooler
• Proportional valve
• How to work
• When the auxiliary brake does not brake
• When an additional brake is just made for braking
• When the auxiliary brake is braking
• When to increase the braking torque
• When to reduce the braking torque
• When to terminate the additional brake
• Electrical part
• Using the retarder
• Braking (trucks with ABS)
• Downhill speed control
• Engine warm up (trucks with ABS)
• Braking (trucks without ABS)
• Warming up the engine (trucks without ABS)
• Features of the brake system
• Controls
• ABS connections
• Downhill speed control
• Communication with EDC system
• Engine braking exhaust throttling device
• MBP signal output
• Heated driver's cab and passenger compartment
• Alert system
• Reinstalling the alarm system

Retarder brake. Disassembly and assembly

• Troubleshooting
• Low braking effect
• Critical details
• External oil leak
• Disassembly and assembly
• Proportional valve
• Oil cooler
• Oil accumulator
• Additional brake

Exhaust throttling device

• Disassembly
• Build
• Adjustment

AD1100P wheel hub with RH730 reducer

• Checking the oil level
• Removing and installing a semiaxis
• Removing the axle shaft
• Removing the planetary gear
• Replacing the planetary gear bearing
• Replacing oil seals
• Removing the hub
• Antilock Brake System (ABS) impulse wheel replacement
• Replacing wheel bearings
• Installing the hub and pre-tightening the bearing
• Installing the planetary gear
• Semiaxis installation

Front axle disc brake hub