Volvo FH / FM with engines of 9.4 / 12.8 liters, service e-manual (in Russian), volume 2

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