Volume 2 provides repair information:

• - steering
• - gearboxes;
• - suspension, brakes, body;
• - electrical equipment.

Contents

Steering

• Dual steering
• Power steering pump
• Power steering
• Hydraulic fluid reservoir
• Power steering cylinder
• Signal lamp / symbol on the display
• Steering wheel
• Replacing the steering wheel
• Removing the steering gear
• Installing the steering gear
• Automatically adjustable steering angle stop
• Left turn check
• Check when turning right
• Replacement
• Repair of steering levers
• Replacing the steering arm
• Replacing intermediate arm bearings
• Replacing the longitudinal tie rod
• Steering knuckle
• Overhaul of the steering knuckle
• Kingpin pivot adjustment
• Replacing the power steering pump
• Rear axle with electric steering
• Description
• Hydraulic diagram
• Supporting middle axle right turn
• Supporting middle axle, left turn
• Cart bridge right turn
• Bogie bridge, left turn

Gearboxes

• Manual transmission
• Manual transmission specifications
• Tightening torques for connections
• Description of the manual transmission
• Gear selector housing
• Pneumatic system
• Gear lever
• Air filter
• Demultiplier cylinder
• Range multiplier control valve
• Range multiplier crankcase blocking valve
• Lock cylinder
• Control housing blocking valve
• Demultiplier blocker
• Divider cylinder
• Divider control valve
• Divider blocking valve
• Electrical system
• Lubrication system
• Oil pump
• Oil cooler
• Disassembly and assembly of the gearbox
• Replacing the drive shaft seal ring
• Input shaft overhaul
• Input Shaft Lubrication
• Major overhaul of the main shaft
• Reverse shaft overhaul
• Overhaul of the intermediate shaft
• Replacing the output shaft seal
• Removing the transmission oil filter housing
• Installing the transmission oil filter housing
• Oil pump overhaul
• Overhaul of the transmission mechanism of the demultiplier
• Demultiplier cylinder overhaul
• Shift cable drive system
• Removing and installing control housing
• Overhaul of the control unit housing
• Removal and installation of a selector of transfers
• Replacing the modified gear selector
• Replacing the gear selector cable
• For Volvo FM cars
• For Volvo FM cars
• For all Volvo FM trucks
• Automatic transmission Powertronic
• Transmission 6-Speed ??Gearbox
• Control units RECU, TECU
• Torque converter
• Power take-off
• Retarder
• Clutches and brakes in gearbox
• Driving force transmission path
• Planetary gears
• Gear ratios
• Interaction of solenoid valves, clutches and brakes
• Pneumatic solenoid valve circuit diagram
• Output shaft ratios
• 1st gear
• 2nd gear
• Shifting gears without losing driving force
• 3rd gear
• 4th gear
• 5th gear
• 6th gear
• R1 reverse gear
• R2 reverse gear
• Display
• Troubleshooting
• Management system
• Lubrication system
• Solenoid and relay valves
• Management system
• Hydraulic circuit diagram
• Main pressure circuit
• Torque converter circuit
• RRV retarder valve
• PWM S 14 valve blocking control
• Engaging power take-off
• Location of sensors
• Gearbox removal
• Installing the gearbox
• Gearbox disassembly
• Gearbox assembly
• Clutch housing repair (type 1)
• Clutch housing repair (type 2)
• Rear cover overhaul
• Cleaning the control valve bodies
• Control valve
• Main discharge valve
• Assembling control valve bodies
• Checking the retarder valve

Suspension

• Leaf springs
• Replacing the front spring
• Replacing the front spring bushings
• Maintenance-free front spring rubber bush
• Front axle level sensor
• Replacing the rear spring
• Air suspension
• Front axle
• Rear axle
• Description of the air suspension system
• Electronically controlled air suspension
• Additional rear axle with adjustable pressure
• Lateral roll compensation
• Raising an additional axle, spinning an additional axle and optimizing traction
• General information
• Drive axle load depending on bellows pressure
• How it works
• Air suspension components
• Control unit
• Operation of ADR vehicles
• Remote control
• Control keys
• Memory key
• Restoring factory level body level
• Locked mode
• Solenoid valve assembly
• Sensors ugly
• Air suspension component locations
• ECS advanced features
• Function 1: prohibit lift height adjustment
• Function 2: lowering the axle when the parking brake is applied
• Function 3: lowering one bridge
• Feature 4: alternative drive heights
• Function 5; loading height M1
• Function 6: loading height M2
• Feature 7: ferry mode
• Feature 8: alternative bridge load sharing
• Function 11: undercarriage lift + 30%
• Push axle vehicles
• Cars with additional axles
• Combinations of ECS additional features
• Schematic diagrams of pneumatic suspensions
• Pneumatic suspension for 4x2 vehicles, tractor unit
• Air suspension for 4x2 vehicles, truck
• Full air suspension for 4x2 vehicles
• Rear air suspension for vehicles with 6x2 wheel arrangement and rear air suspension
• Suspension for vehicles with wheel arrangement 8x2 (2 front axles), bogie axle
• Front air suspension for 6x2 vehicles, supporting axle
• Complete air suspension for 6x2 vehicles, bogie
• Full air suspension for 6x2 vehicles, supporting axle
• Full air suspension for 6x4 vehicles
• Rear air suspension for 6x4 and 8x4 vehicles (2 front axles)
• ECS Troubleshooting
• Car tilts (longitudinal or transverse)
• The car tilts and tries to correct its tilt
• Hiss
• The lift does not work
• Lowering does not work
• Vehicle raised too high
• Rear / front suspension never stops lifting
• Rear / front suspension never stops dropping
• It takes an abnormally long time to pump up the pneumatic system
• Manual control from the remote control does not work
• Truck lift not working
• Lowering cart does not work
• Axle load balancing does not work
• Replacing the air suspension level sensor
• Front axle
• Installation
• Level sensor calibration
• Cart valve replacement
• Replacing the front axle solenoid valve
• Rear axle solenoid valve replacement
• Replacing the solenoid valve of a triple bridge
• Replacing the control unit
• Replacing pressure sensors
• Removing and Installing the Front Counter Bar
• Removing and installing front torque rod
• Replacing air suspension cylinders
• Replacing the drive axle air spring
• Replacing the drive axle air suspension level sensor
• Replacing the rear shock absorber
• Replacing the anti-roll bar
• Replacing the rear air suspension beam
• Rear rod bushing replacement
• Replacing the strut and attachment to the anti-roll bar frame
• Repair of the axle and rubber bush of the anti-roll bar
• Replacing the front axle anti-roll bar rubber mounts
• Suspension bogie lifting device
• Checking the working pressure of the lifting device
• Changing the hydraulic fluid in the lifting device
• Replacing the lifting bellows
• Lifting valve removal and installation
• Replacing the hydraulic cylinder of the lifting device
• Replacing the hydraulic valve of the lifting device
• Removal and installation of the electric motor and pump of the lifting device

Brakes

• Disc brake specifications
• Brake disc
• Brake pads
• Brake cylinders
• Tightening torque
• Adjusting torques and clearances
• Cracks in one-piece brake discs
• Cracked, lightweight brake discs
• Various combinations of brakes and their locations on RAD-L90 4x2, RAD-A4 4x2
• Various combinations of brakes and their location on RAPD-A6 6x2 vehicles
• Various combinations of brakes and their location on RADT-A8 6x2, 8x2 cars
• Different combinations of brakes and their locations on RADD-A8 6x4, 8x4, RADO-BR, RADD-TR 6x4, 8x4
• Decoding of vehicle variants
• Description of disc brakes
• Radial brake markings
• Brake disc device
• Brake pad device
• Wear sensor device
• Reflector / mudguard assembly
• Design changes
• Disc brake ELSA195A
• Disc brake ELSA225-1A
• Disc brake ELSA225-3A
• Disc brake ELSA225-3R
• Function
• Automatic adjustment
• Using brakes without adjustment
• Using adjustable brakes
• Manual adjustment
• Troubleshooting disc brakes
• Symptoms that may be detected by the driver while driving
• Faults identified at the workshop
• Repair of front disc brakes
• Replacing the pad wear sensor
• Replacing the control unit
• Replacing brake pads
• Replacing the brake disc
• Brake disc splitting method
• Caliper removal and installation
• Measuring the wear of the guide bushings
• Replacing the guide bushing seals
• Rear disc brake repair
• Replacing the pad wear sensor
• Replacing the control unit
• Replacing the brake disc (hub removed)
• Caliper replacement
• Measuring the wear of the guide bushings
• Replacing the guide bushing seals
• Repair of additional axle disc brakes
• Replacing the pad wear sensor
• Measuring the wear of the guide bushings
• Replacing the guide bushing seals
• Pneumatic braking system
• Brake system schematics
• Schematic diagrams of the third generation electronic brake system (EBS)
• EBS functional check
• Checking trouble codes
• Switch, TCS
• Trailer brake switch
• Differential lock switch
• Parking brakes
• Switch, lift start
• Low pressure switch in the parking brake reservoir
• Trailer communication channel ISO 11992
• Wheel speed sensor
• Brake pad wear sensor
• Foot brake valve
• Modulator and trailer modulator
• ABS solenoid valve
• Replacing the front modulator
• Replacing the rear modulator
• Replacing the trailer modulator
• Replacing the additional axle modulator
• Compressor and air dryer
• Compressor specifications WABCO 636
• Changing parameter values ??
• Compressor, tightening torques
• WABCO 318 compressor specifications
• Changing parameter values ??
• Compressor tightening torques
• WABCO 704 compressor specifications
• Changing parameter values ??
• Compressor, tightening torques
• Compressor description
• Compressor, design
• Compressor, functioning
• Compressor, power reduction function
• Air dryer specifications
• Switch-on and switch-off pressure (values ??for electronically controlled air dryer)
• Description of the air dryer
• Electronic dehumidifier functions
• Dehumidifier control
• Compressor control
• Maintenance checks
• Air leak check / warning
• Organization of fault code management
• Troubleshooting the air dryer
• Inspection procedure
• Solenoid valves, check
• Compressor replacement
• 1SOMP530, 2SOMP900, 2SOM1080
• Replacing the air dryer
• Replacing the drain valve
• Replacing the foot brake valve
• Checking the load sensing valve (vehicle with leaf springs rear suspension)
• Parking brake
• Parking brake test
• Replacing the parking brake actuator
• Trailer parking brake
• Anti-lock braking system (ABS)
• Functional check of the ABS system
• ABS warning light (5009)
• Trouble code management
• Information Channel SAEJ1708
• Wheel speed sensor, ABS (7057)
• ABS solenoid valves (6013)
• Trailer, ABS
• Signs of malfunctioning ABS

Body

• Body and cab frame
• Cab Specifications
• Cab tilt unit
• Spring travel
• Cabin
• Cab rollover
• Fluid leak
• Bleeding hydraulic system
• Cab tilt pump
• Cab tilt cylinder
• Safety valve
• Cab lock
• Cab tilt
• Hand pump control valve in up position
• Hand pump control valve in down position
• Lowering the cab
• Replacing the cab tilt cylinder
• Replacing the cab tilt cylinder seals
• Checking the pressure in the cab tilt pump
• Replacing the cab tilt pump
• Replacing the electric cab tilt pump
• Replacing the cab tilt pump control valve
• Cab suspension
• Removing and installing lateral vibration stabilizer bar
• Replacing the front shock absorber
• Replacing the front air shock absorber of the cab suspension
• Rear mechanical shock absorber adjustment
• Replacing the level control valve
• Front panel and bumper
• Replacing the front panel sealing strip
• Removing and installing bumper
• Doors
• Replacing the outer door seal
• Replacing the power window
• Glass and mirrors
• Windshield replacement
• Cab side glass replacement
• Replacing the rearview mirror glass
• Replacing the rearview mirror motor
• Replacing the dead zone mirror
• Replacing the power mirror wiring harness
• Replacing the rear view mirror bracket
• Seat
• Seat description
• Seat valve
• Seat cushion fan replacement
• Replacing the backrest fan
• Replacing the backrest heater cushion
• Seat suspension replacement
• Replacing the vertical shock absorber
• Replacing the height limiter
• Rear caliper replacement
• Replacing the stopper
• Replacing the carriage clamp
• Replacing the seat frame
• Seat belt replacement
• Interior fittings
• Removing control panel items
• Removing the switch panel
• Removing moldings and grilles
• Removing the Passenger Side Panel
• Removing the air inlets
• Replacing the seat belt buckle lever
• Connecting pipes at the front of the cab
• Vehicle with electronic braking system (EBS)
• A car with a conventional braking system
• Climate control system
• Description
• Heating system components
• Air conditioning components (for MCC and ESS)
• Management system components
• Control panel
• Fan
• Air distribution
• Temperature
• Air conditioning
• The cab is too cold or too hot
• Air conditioner turns on despite cold weather
• The windows fog up in the AUTO position
• Fan speed too high
• Dripping water
• Mechanical noise
• Control system repair
• Replacing the stepper motor (for BAS, MCC and ECC)
• Replacing control cables (for HEAT and ACMAN)
• Knowing and installing an air conditioning system
• Replacing the air conditioning heat exchanger
• Replacing the air conditioner fan motor
• Replacing the temperature sensor
• Replacing the air conditioning temperature sensor
• Evaporator temperature sensor replacement
• Replacing the solenoid valve
• Replacing the heater control valve
• Expansion valve replacement
• Evaporator replacement
• Parking heater
• Description
• Removing and installing a parking heater
• Replacing the control unit
• Replacing the temperature sensor
• Replacing the glow plug
• Replacing the flame indicator
• Combustion unit replacement
• Replacing the combustion air fan
• Replacing the fuel pump
• Replacing the overheating protection

Electrical equipment (wiring diagrams)

• Battery
• Battery types
• Low maintenance batteries
• HDX Batteries
• Battery properties
• State of charge
• Capacity
• Influence of temperature
• Freezing point
• Common battery problems
• Charging the batteries
• Electrolyte
• Electrolyte mixture
• Adding electrolyte
• Electrolyte density measurement
• Battery replacement
• Generator
• generator tightening torque
• Generator signal characteristics
• Replacing the voltage regulator
• Dismantling the starter motor
• Checkout
• Excitation winding
• Brush holder
• Bendix clutch, planetary
• Starter gear
• Front bearing housing
• Fork lever
• Control relay
• Starter relay
• Assembling the starter motor
• Functional check
• Fuses
• Replacing the fuse and relay box
• Instrumentation
• Layout of components
• Display
• Information display symbols
• Meters
• Indicators
• Dashboard replacement
• Tachograph replacement
• Ground terminals
• Relay
• Harness & Component Index
• Wire harness locations
• Side light wiring harness (chassis side)
• ABS wire harness
• ESP harness
• Upper wiring harness
• Cab side light wiring harness
• Door wiring harness
• Engine wire harness
• Rear suspension wiring harness
• Trailer harness
• Cab harness
• Transmission wiring harness
• Rear lighting wiring harness
• Bulkhead wire harness
• Dashboard wiring harness
• Undercarriage lifting harness
• Tire pressure monitoring system harness
• Headlamp wiring harness
• Trailer brake wire harness
• Front chassis wiring harness
• Rear chassis wiring harness
• Electrical center wire harness
• Urea injection (SCR) harness
• Battery cable harness in the battery box
• Battery harness to engine
• Battery cable harness to cab
• Rear axle wiring harness