Volvo FH / FM with engines of 9.4 / 12.8 liters, service e-manual (in Russian), volume 1

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