The first volume provides information on:

• - maintenance
• - engine repair
• - clutch and axle repair
• - repair of wheels and tires

Contents

General information

• Truck ID
• Standard tightening torques
• Requirements for oils, greases and technical fluids
• Engine oil
• Gear oil
• Grease
• Coolant
• Brake fluid
• Fuel requirements
• Refueling containers and materials
• Engines
• Oil change volumes
• Clutch
• Gearboxes
• Manual transmissions
• Manual gearboxes ZF
• EATON manual transmissions
• VOLVO automatic transmissions
• ALLISON automatic transmissions
• Bridges
• Heavy rear axles
• Lightweight rear axles
• Other rear axles
• Drive front axles
• Transfer cases
• Power take-offs (flywheel mounted)
• Hydraulic retarder
• Coolant
• Other components

Maintenance

• Maintenance types
• Basic service
• Additional work and lubrication
• List of additional works
• Engine oil change intervals
• D9B engine oil change intervals (EURO 3)
• Oil change intervals for D9B engine (EURO 4 and EURO 5)
• Oil change intervals for D13A (EURO 3 and EURO 4) engine
• Gearbox oil change intervals
• Manual transmissions
• Manual gearboxes ZF
• EATON manual transmissions
• VOLVO automatic transmissions
• ALLISON automatic transmissions
• Axle oil change intervals
• Heavy rear axles
• Lightweight rear axles
• Drive front axle
• Coolant change intervals
• Replacement intervals for other components
• Transfer case
• Power take-off (flywheel mounted)
• Hydraulic retarder
• Fuel filter
• Water separator
• Water separator
• Fuel tank ventilation filter
• Air cleaner filter insert
• Particulate filter (CRT)
• Mechanical compressor
• Drive belts

VOLVO engine range

• Lineup

D9B engine

• Specifications
• Cylinder block
• Cylinder head
• Cylinder head bolts
• Cylinder liner
• Piston
• Piston rings
• Compression Rings
• Oil scraper ring
• Valve mechanism
• Valves
• Valve guides
• Valve seats
• Valve seat arrangement
• Rocker arms
• Valve Springs
• Engine timing gears
• Timing gears
• Camshaft
• Camshaft bearings
• Crank mechanism
• Crankshaft
• Main bearing journals
• Thrust washers (thrust bearing)
• Main bearing housings
• Connecting rod bearing trunnion
• Connecting rod bearing housings
• Connecting rod
• Flywheel installed
• Flywheel housing installed
• Lubrication and oil units
• Oil pressure
• Oil temperature
• Lubrication pump
• Oil filter
• Oil valves
• Fuel system
• Feed pump
• Bypass valve
• Fuel quantity
• Unit injectors
• Intake and exhaust system
• Charging pressure
• Exhaust pressure regulator
• Turbocharger
• Actuator (bypass valve)
• Pressure drop indicator
• Engine braking system
• EPG / EPGC
• VEB
• Heat retention function
• Exhaust back pressure
• Cooling system
• Thermostat
• VISCO electric fan
• Coolant
• Engine management system
• Coolant temperature sensor
• Inlet temperature sensor
• Engine oil temperature sensor
• Charge air temperature sensor
• Turbo pressure sensor
• Pressure drop indicator
• Camshaft sensor
• Flywheel sensor
• Crankcase pressure sensor
• Tightening forces and schemes
• Oil pan. Tightening torques
• Pump nozzle. Tightening torques
• Description of D9B engine
• Engine identification
• Engine
• Cylinder head
• Camshaft and valve train
• Cylinder block
• Cylinder head guides
• Stiffening frame and oil pan
• Crank mechanism
• Crankshaft, vibration damper, flywheel
• Piston, cylinder liner and connecting rod
• Distribution mechanism
• Engine transmission
• Belt drive
• Engine lubrication system
• Oil pump and oil cooler
• Oil filter housing and valves
• Piston cooling system
• Fuel system
• Fuel supply system, principle of operation
• Fuel system, components
• Unit injectors
• Intake and exhaust system
• Engine brake
• Exhaust pressure regulator (EPG)
• Volvo engine brake (VEB)
• Opening valves
• Engine braking
• Crankcase ventilation
• Closed crankcase ventilation (CCV)
• Open crankcase ventilation
• Cooling system
• Coolant pump and thermostat
• Coolant fan
• Fan operation
• Fan control
• Coolant temperature
• Pneumatic system
• Air conditioning
• Charge air temperature
• Retarder
• Compact retarder
• Retarder POWERTRONIC
• EECU temperature
• Management System
• Engine management system
• Electronic starter function
• Ems controlled starter motor
• Engine Wiring & Grounding
• D9B engine fault codes in EURO 4 configuration
• Types of MID 128 trouble codes
• Active and inactive trouble code
• Fault code table
• Freeze frame
• Alerts
• Display
• Signal lights and buzzer
• Engine protection
• Power reduction
• Engine shutdown
• Exhaust gas failures
• Self-clearing trouble codes
• Removal and engine installation
• Cylinder head
• Compression test in cylinders
• Removing and installing cylinder head
• Checking the cylinder head under pressure
• Removing and installing valves
• Replacing the valve seat ring
• Checking valve guides for wear
• Replacing the valve guides
• Check valve rocker bushings
• Valve rocker bushings
• Rocker Bush Roller
• Replacement of rocker arms
• Adjustment of valves, unit injectors
• Cylinder block
• Replacing liners and pistons
• Moving engine system
• Replacement of main bearings
• Replacing the connecting rod bearings
• Replacing the crankshaft rear oil seal
• Replacing the front crankshaft oil seal
• Replacing the front crankshaft cover seal
• Checking the deformation of the flywheel housing
• Checking the flywheel
• Flywheel replacement
• Replacing the flywheel ring gear
• Checking the flywheel sensor position
• Timing gear mechanism
• Checking the camshaft for wear
• Replacing the camshaft bearing housings
• Replacing timing gears
• Replacing the timing gear cover gasket
• Replacing the camshaft shield
• Replacing the timing gear upper cover O-ring
• Replacing the camshaft oil seal and flywheel
• Lubrication system
• Removing and installing oil pan
• Removing and installing oil pump
• Replacing the oil discharge line
• Replacing the oil filter
• Replacing the oil cooler cover gasket
• Checking the oil cooler under pressure
• Replacing the oil cooler bypass valve
• Replacing the piston cooling stop valve
• Replacing the piston cooling nozzle
• Replacing the bypass valve full of new oil filter
• Replacing the pressure reducing valve
• Replacing the piston cooling control valve
• Replacing the oil cooler bypass valve
• Replacing the oil pressure relief valve
• Fuel system
• Replacing the fuel pump
• Replacing the fuel filter
• Replacing the water separator filter
• Replacing the fuel filter housing
• Checking the water separator drain valve
• Checking the fuel supply pressure
• Removing and installing the fuel level sensor in the tank
• Cleaning the fuel tank
• Replacing the bypass valve
• Checking the unit injector preload
• Replacing the unit injector
• Replacing the copper sleeve of the unit injector
• Replacing the ball seat of the unit injector
• Intake and exhaust system
• Replacing the intake manifold gasket
• Replacing the exhaust manifold gasket
• Cleaning the particulate filter insert
• Replacing the bypass valve pressure block
• Replacing the crankcase ventilation separator
• Replacing the crankcase ventilation separator valve
• Exhaust gas cleaning system
• General information
• Main system components
• Normal operation
• Low level of urea solution in the tank
• Normal cutoff
• Volvo ADR cars
• Tank
• Heating urea solution
• Pouring urea solution
• Urea solution
• Pump unit
• Filter housing
• Control unit
• Dosage unit
• SCR catalytic converter
• Urea solution hoses
• Handling urea solution
• Cooling system
• Cooling system pressure test
• Replacing the coolant
• External radiator cleaning
• Replacing the coolant pump
• Replacing the thermostat
• Replacing the thermostatic fan
• Replacing belt drives
• Replacing the fan hub
• Finding leaks in the intercooler
• Control unit
• Replacing the control unit

D13A engine

• Specifications
• General information
• Cylinder head
• Cylinder head bolts
• Cylinder block
• Cylinder liner
• Piston
• Piston rings
• Valve mechanism
• Valves
• Valve seats
• Valve seat sockets
• Valve guides
• Rocker arms
• Valve springs
• Engine timing gear
• Camshaft bearings
• Crank mechanism
• Crankshaft
• Root necks
• Thrust washers (thrust bearing)
• Main bearing shells
• Main bearing journal
• Main bearing shells
• Connecting rod
• Flywheel mounted
• Flywheel housing, mounted
• Lubrication oil system
• Oil pressure
• Oil temperature
• Oil filter
• Oil valves
• Fuel system
• Fuel pump
• Bypass valve
• Unit injector
• Intake and exhaust system
• Boost pressure
• Euro3
• Euro 4
• Euro 5
• Turbocharger
• Actuator (bypass valve)
• Pressure drop indicator
• Exhaust pressure regulator
• Keeping warm function
• Engine brake
• Epg / epgc
• Veb
• Exhaust gas back pressure
• Cooling system
• Thermostat
• Coolant
• Electronic viscous fan
• Engine management system
• Oil temperature sensor in Volva engine
• Coolant temperature sensor
• Inlet temperature sensor
• Charge air temperature sensor
• Boost pressure sensor
• Pressure drop indicator
• Camshaft sensor
• Flywheel sensor
• Crankcase pressure sensor
• Tightening torques and sequence
• Stiffening frame
• Switchboard
• Distribution mechanism
• Flywheel and gearbox housing
• Timing gear cover, top
• Flywheel
• Cover, crankshaft seal
• Vibration damper
• Cylinder head
• Bearing caps, camshaft / rocker shaft
• Valve cover
• Oil pan. Tightening torques
• Oil cooler
• Oil cooler cover
• Tightening torques for unit injectors
• Intake and exhaust system tightening torques
• Fan hub tightening torques
• Tightening torques for sensors
• D1 engine description
• Engine identification
• Cylinder head
• Cylinder block
• Stiffening frame and oil pan
• Cylinder head guides to block
• Piston, cylinder liner and connecting rod
• Camshaft and valve train
• Crankshaft, vibration damper, flywheel
• Engine transmission
• Engine Transmission Intermediate Gear
• Carters
• Engine PTO drive
• Engine mount
• Lubrication and lubrication system
• Oil pump and oil cooler
• Piston cooling system
• Fuel system
• Unit injectors
• Intake and exhaust system
• Air intake and air filter
• Starter component
• Exhaust manifold and turbocharger
• Engine retarder
• Electric control of engine brake-retarder
• EPG engine retarder
• EPGC engine retarder
• VEB engine retarder
• Engine braking - schematic description
• Exhaust pressure regulator (EPG / ATR)
• Release pressure regulator EPG / EPGC
• Decrease braking
• Release pressure regulator EPG / EPGC with retarder
• Automatic smooth control of additional brakes
• Additional braking 40-100%
• Full braking power
• Braking stroke
• Decrease braking
• VEB engine retarder
• Camshaft and output rocker arms
• Control valve
• Normal vehicle movement
• Engine retarder activation
• Disable VEB
• Valve opening during engine compression
• Decrease braking
• Veb in combination with automatic transmission and / or retarder
• Automatic smooth control of additional brakes
• 40-100% extra braking
• Full braking force
• Cruise brake
• Decrease braking
• Intermediate cooling
• Crankshaft ventilation
• Closed crankshaft ventilation (CCV)
• Open ventilation of the crankshaft
• Cooling system
• Coolant pump and thermostat
• Drive belts
• Cooling fan
• Coolant temperature
• Pneumatic system
• Air conditioning system (AU)
• Charge air temperature
• Retarder
• Compact retarder
• POWERTRONIC retarder
• EECU temperature
• Management system
• Engine management system
• Electronic start function
• Ems controlled starter
• Engine wiring and grounding
• Types of MID 128 trouble codes
• Fault code table
• Warnings
• Signal lights and buzzer
• Engine protection
• Exhaust related problems
• Self-clearing DTCs
• Removal and engine installation
• Cylinder head
• Compression test in cylinders
• Removing and installing cylinder head
• Removing and installing valves
• Replacing the valve seat ring
• Checking valve guides for wear
• Replacing the valve guides
• Check valve rocker bushings
• Valve rocker bushings
• Rocker bush roller
• Replacement of rocker arms
• Adjusting valves and unit injectors
• Adjusting the brake rocker
• Cylinder block
• Replacing liners and pistons
• Replacement of main bearings
• Replacing the crankshaft rear oil seal
• Replacing the front crankshaft oil seal
• Replacing the front crankshaft cover seal
• Checking the deformation of the flywheel housing
• Checking the flywheel
• Flywheel replacement
• Replacing the flywheel ring gear
• Checking the flywheel sensor position
• Timing gear mechanism
• Checking the camshaft for wear
• Lubrication system
• Removing and installing oil pan
• Removing and installing oil pump
• Replacing the oil discharge line
• Replacing the oil filter
• Replacing thermostat controlled valve
• Replacing the piston cooling nozzle
• Full flow oil filter bypass valve replacement
• Replacing the oil pressure relief valve
• Fuel system
• Replacing the fuel pump
• Replacing the fuel filter
• Replacing the water separator filter
• Replacing the fuel filter housing
• Removing and installing fuel level sensor
• Cleaning the fuel tank
• Replacing the bypass valve
• Checking the unit injector preload
• Replacing the unit injector
• Replacing the copper sleeve of the unit injector
• Replacing the ball seat of the unit injector
• Intake and exhaust system
• Replacing the intake manifold gasket
• Replacing the exhaust manifold gasket
• Replacing the solenoid valve of the retarder
• Replacing the solenoid valve (VEB)
• Replacing the Compression Brake Control Valve
• Replacing the engine brake flap housing
• Replacing the engine brake actuator cylinder
• Exhaust Pressure Regulator Replacement
• Replacing the control valve (VEB)
• Replacing the turbocharger
• Replacing the bypass valve pressure block
• Replacing the air filter insert
• Replacing the crankcase ventilation separator
• Cooling system
• Replacing the coolant
• External radiator cleaning
• Replacing the coolant pump
• Replacing the thermostat
• Replacing the thermostatic fan
• Replacing belt drives
• Replacing the fan hub
• replacing the intercooler
• Control unit

Clutch

• Specifications
• Clutch disc marking
• Checking the clutch for wear
• Clutch repair
• Replacing the clutch disc
• Replacing the release bearing and clutch fork
• Replacing the clutch valve block
• Replacing the clutch position sensor
• Replacing the clutch servo

Bridges

• General information
• Tightening torques for the RS1344SV (DS44S) bridge
• Final transfer DS44S
• MOCTRS1344SV
• Differential lock
• Tightening torques for bridge RS1344SV (DS44S) (dt100h, ds70h)
• DT100H Final Drive
• Front axle RT2610HV / RT3210HV (DT100H, DS70H)
• Final Drive DS70H
• Rear axle RT2610HV / RT3210HV
• Tightening torques for bridge RSS1344B
• Tightening torques for RTS2370A axle
• Front rear axle
• Rear (last) axle
• Description of bridges
• Bridges RT2610HV, RT3210HV AND RTH2610B
• General information
• Final drives, front / rear
• Pinion gear
• Pinion bearing
• Pinion bearing
• Lateral transmission clearance
• Engagement
• Transfer case
• Input shaft
• Differential locks
• Hub reducer
• Wheel bearings
• Rear axle RSS1344B
• Main show
• Half-shafts
• Differential lock mechanism
• Overhaul of the wheel reducer
• Replacing the drive gear O-ring
• Overhaul of the output shaft
• Removal and installation of the final transfer
• MOCTRSS1344B
• MOCTRS1356SV
• Front and rear axles RT2610HV, RT3210HV and RTH2610B
• Differential box repair (axle RSS1344B)
• Differential box repair {front axles RT2610HV, RT3210HV and RTH2610B)
• Differential box repair (rear axles RT2610HV, RT3210HV and RTH2610B)

Wheels and tires

• Wheel repair
• Checking the hub of the drive and additional axle
• Rear wheel hub replacement
• Replacing the wheel hub of the additional middle axle
• Replacing the hub seal
• Replacing the bearing and seal
• Hub cover
• Replacing the wheel stud
• Tire pressure monitoring
• Fitting the wheel
• Camber and toe
• Toe-in (with the vehicle equipped) of the front wheels
• Camber (with the vehicle equipped) of the front wheels
• Steering angles (with the vehicle equipped) of the front wheels
• Rear wheel specification