WSM - Maintenance Instruction Part - 1 Truk - en PDF

00:03-07/1
Issue 11 en
Maintenance instructions part 1
4 series
Group 0 - 9
100309
© Scania CV AB 2005, Sweden

1 585 442
Contents
Contents
Changes from the previous issue .................... 4
0 General Inspection form ............................................... 5

Safety .............................................................. 6
0-01 Chassis lubrication .......................................... 8
0-02 Tool kit .......................................................... 24
0-03 Correct Operator's Manual ............................ 25
1 Engine 1-01 Oil change ..................................................... 27

1-02 Oil cleaner ..................................................... 29
1-03 Renewal of insert filter.................................. 38
1-04 Crankcase ventilation.................................... 39
1-05 Checking the poly-V-belt .............................. 39
1-06 Checking belt tension.................................... 41
1-07 Valve clearances and PDE unit injectors,
9 litre engine with 5 cylinders....................... 42
1-08 Valve clearances 9, 11 and 12 litre engines,
engines with 6 cylinders ................................ 48
1-09 Valve clearances 14 and 16 litre engines ...... 50
1-10 Scania PDE unit injectors ............................. 53
1-11 Scania HPI unit injectors .............................. 56
1-12 Air cleaner..................................................... 58
1-13 Intake manifold ............................................. 60
2 Cooling system 2-01 Coolant .......................................................... 61

2-02 Renewing the coolant filter ........................... 63
2-03 Measuring corrosion inhibitor....................... 63
3 Fuel and exhaust systems 3-01 Renewal of fuel filter, bleeding..................... 70

3-02 Gas engine..................................................... 79
3-03 Scania particle filter ...................................... 83
4 Clutch 4-01 Fluid level in clutch control .......................... 85

4-02 Renewing the clutch fluid ............................. 86
4-03 Checking clutch wear.................................... 87
4-04 Torque converter, checking the oil level ....... 88
Oil change and filter renewal ........................ 88
Checking torque limitation ........................... 90
5 Gearbox 5-01 Manual gearbox............................................. 91

5-02 Automatic gearbox........................................ 93
5-03 Opticruise .................................................... 100
5-04 Transfer box ................................................ 100
5-05 ZF-transmatic .............................................. 101
6 Propeller shafts 6-01 Checking propeller shafts, support

bearings and universal joint cross ............... 104
6-02 Checking bearing retainers.......................... 104
2 © Scania CV AB 2005, Sweden 00:03-07/1

Contents
7 Front axles 7-01 Changing oil in axle gear ............................ 105

7-02 Hub reduction gears .................................... 106
7-03 Checking front vehicle unit......................... 107
7-04 Measuring toe-in ......................................... 109
8 Rear axles 8-01 Changing oil in axle gear ............................ 110

8-02 Tag axle lift ................................................. 112
8-03 Tag axle 6x2, 8x2 ........................................ 112
9 Hubs and Wheels 9-01 Hub reduction gears .................................... 113

9-02 Checking front wheel bearings ................... 116
9-03 Check tightening wheel nuts ....................... 117
9-04 Checking the tyres....................................... 118
00:03-07/1 © Scania CV AB 2005, Sweden 3

Changes
Changes from the previous issue

1-02 Oil cleaner, new design, page 33-37.
1-07 Valve clearances, 9-litre engine, page 42-47.
3-01 Changing fuel filter, bleeding, 9 litre engine, page 75.
5-01 Changed oil volumes, page 92.

General
0 General
Inspection form
The following inspection reports can be found in
group 0:
• Maintenance Programme - Preface

• D Inspection
• R Inspection
• S Inspection
• M Inspection
• L Inspection
• X Inspection
Make copies of the reports as required.

1
1 Fill in the customer details.
2 After completing one inspection step, put a
cross in that column and fill in the values
where applicable. Fill in the thickness of the
brake linings for example.
3 Whenever it is necessary to make a remark,
write the step number, the remark and the
proposed action in the notebook for the
2
relevant inspection.
Vehicle-specific inspection reports can also be 13 10
printed using the PC software Scania Main.

Anmärkningar
3
100257

Safety
Safety
Vehicles with air suspension

Always support vehicles with air suspension
under the frame. Otherwise, the vehicle may
drop as the air pressure in the bellows is
reduced. Do not walk under a vehicle that is
raised on a jack only. Follow the instructions in
the Workshop Manual, Lifting and supporting
on stands.
Safety measures
• Use reliable and correctly dimensioned
stands, struts and locks with standard
locking devices.
• Stands and struts must be sturdy.
• Lifting tools must have been inspected and
approved for use.
For more information on safety measures, see

Workshop Manual, Safety in the workshop,
main group 00.

General
0-01 Chassis lubrication

Lubricating with an oil can
• Front grille hinges and latches
• Cab tilt lock
• Door stop
• Door hinges
• Linkage for load-sensing valve
• Storage compartment latch
• Bonnet latch (T vehicles)
Lubricating with grease gun

Use universal grease for lubrication points on
the chassis and for wheel bearings and spring
bearings.
Grease grade: Grease consistency NLGI 0 to
NLGI 2.
Note: When lubricating with grease, make sure

grease exudes from all the bearing cups. This
will ensure good lubrication.

General
Lubrication points
1
1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
18 6
6 1
1 2 6
2 6
3 3
4 4
8 8
7 7
6
6
9 9
100742
7
100 877
1 Spring bolt
2 Brake slack adjuster
3 Brake camshaft
4 King pin bearing (with raised front axle)
6 Spring shackle
7 Universal joint
8 Support bearing
9 Sliding joint
18 Steering arm
See Lubricating with a grease gun

General
Lubrication points 4x4 Z, 6x6 Z
1
1
2
2
3 3
4 4
15 15
6
7
9
6
7
9
124 649
1 Spring bolt
3 Brake camshaft
4 King pin bearing (with raised front axle)
6 Spring shackle
7 Universal joint
9 Sliding joint
15 Halfshaft joint (AMD 900)

General
Lubrication points 4x2 A/B
2 2
3 3
00_1526
3 Brake camshaft
7 Universal joint

General
1 1
2 2
3 3
6 6
100 809
1 Spring bolt
3 Brake camshaft
6 Spring shackle
7 Universal joint

General
Lubrication points 6x2 A/B, 8x2 A/B
2 2
3 3
3 3
2
2
00_1525

3 Brake camshaft
7 Universal joint

General
1 1
7
3 3
2 2
6
6
10
10
11
3
3 2
2
100258
1 Spring bolt
3 Brake camshaft
6 Spring shackle
7 Universal joint
10 Balance arm
11 Tag axle lift

General
Lubrication points 6x4 Z, 6x6 Z, 8x4 Z, 8x8 Z
2 2
3 3
17 17
7
2 2
3 3
100741

3 Brake camshaft
7 Universal joint
9 Sliding joint
17 Spring bearing

General
Lubrication points 6x4 A/B, 8x4 A/B
2 2
3 3
2 2
3 3
100740

3 Brake camshaft
7 Universal joint
9 Sliding joint

General
Lubrication points 6x2/4 A/B, 8x2/4 A/B
7
18
2 2
3 3
4 4
2 2
3 3
104 865

3 Brake camshaft
4 King pin bearing (with raised axle)
7 Universal joint
9 Sliding joint
18 Steering arm and drop arm

General
Lubrication points 6x2*4 A/B, 8x2*6 A/B
9
7
2 2
3 3
4
4
2 2
3 3
104 866

3 Brake camshaft
7 Universal joint
9 Sliding joint

General
Lubrication points 8x4*4 A/B

3 Brake camshaft
7 Universal joint
9 Sliding joint

General
Lubrication points, fifth wheel
104 912
Clean surface of fifth wheel and check it for wear before greasing. See group 19-02 Fifth
wheel.
See Lubricating with a grease gun.
Note: Grease the surface of the fifth wheel with grease which can withstand high pressure
e.g. EP with MoS2 or grease with added graphite.
IMPORTANT! Grease fifth wheels with teflon-coated surfaces with an extremely thin layer of
grease after cleaning.

General
Lubrication points, tow hook
104 913
Lubricate with thin oil.

Use preferably VBG Mekolja, a specially produced oil with anti-rust and lubricating
properties or another thin-bodied oil.
Note: Never use grease due to its sticky consistency.

General
Automatic Chassis Lubrication,

ACL
Testing the lubrication system

Grease grade: Grease consistency, Scania ACL
NLGI 0 - NLGI 2
Steps 1-4 apply if the lubrication system is
completely empty.
100295
1 Fill the system by detaching the hose to the
outlet union on the pump. Connect a grease
gun to the hose and fill the system.
2 Make sure there is no lubricant exuding

from the overflow valve and that the
indicator pin is moving.
3 The indicator pin is located on the right-

hand side of the main distributor block.
100299
4 Fill until the lubricant exudes from the
various lubrication points in the chassis.
5 Stop filling the lubrication system.
6 Connect the grease gun to the filler nipple

on the lubricant reservoir.
100300
7 Fill the lubricant reservoir with lubricant.

8 Disconnect the grease gun.

General
9 Start the pump manually by starting the

engine and pushing the button behind the
plastic cover in the housing under the
lubricant reservoir.
100295
10 The pump will start. Walk around the
chassis and inspect for leaks.
11 Conduct a road test and make sure none of

the hoses are damaged at their end positions
for the moving parts.
12 Relevant lubrication points: see group 19,

"Automatic Chassis Lubrication ACL".
Other points such as universal joints and
sliding joints are lubricated with a grease
gun.

General
0-02 Tool kit

The vehicle tool kit can vary depending on the specification.
00_1528
1 Bulbs and fuses Disc wheel

2 Screwdriver handle with three bits. One 5 Rim nut wrench
with blade for straight slot at one end and 6 Support for rim nut wrench
Phillips cross at the other. Two bits for the
Torx system.
3 Jack
4 Handle for the jack, rim nut wrench and cab
Spoke wheel
tilting.
7 Locking tool
8 Opening tool
9 Handle for rim nut wrench
10 Rim nut wrench

General
0-03 Correct Operator's Manual

The vehicle comes with an Operator's Manual including booklets corresponding to the vehicle
specification. The booklets are kept in a special binder.
00_1527
The Operator's Manual is divided up into the following booklets:
Order no. Title

OM-00 Data sheet
OM-01 Driver's Instructions
OM-04 Maintenance and care
OM-05 Opticruise
OM-06 All-wheel drive 4x4 and 6x6
OM-08 ABS/TC
OM-09 Allison automatic gearbox
OM-10 ADR
OM-11 Maintenance programme
OM-13 Instructions for recovery
OM-14 Auxiliary brake system with Scania Retarder
OM-19 CTT operation unit for auxiliary heater
OM-20 VPS, alarm system
OM-21 Disc brakes and Scania EBS
OM-22 Air suspension
OM-23 EDC
OM-24 Airbag and belt pretensioner
OM-25 Changing wheels
OM-26 Gas engine

General
Order no. Title

OM-27 Trip Computer
OM-30 Scania particle filter
OM-32 Immobiliser
OM-33 Manual gearbox with torque converter, ZF

Engine
1 Engine
1-01 Oil change

Oil grade: Oils, refer to booklet 00:03-09.
! WARNING!
Beware of hot oil! Wear protective

gloves and goggles.
IMPORTANT! Help protect our environment!

Avoid spillage. Use a collecting vessel.
1 Drain the oil.

2 Change the oil filter.
3 Clean the magnet and renew the sealing
washer. Fill with oil, see next page for oil
capacities.

Engine
Oil capacities
Engine type Volume
9 litre engine, 5 cylinders 30-37 litres
9 litre engine 23-30 litres
11 litre engine, 2 valves per cylinder 23-30 litres
11 and 12 litre engines, 4 valves per cylinder 28-35 litres
Note: The values are approximate. Check with

dipstick and top up if necessary.
Place the oil dipstick in the correct position. You
should be able to feel the dipstick, and not the
handle, "stop" in the oil sump.
IMPORTANT! Make sure that the oil is suitable

for all variations in outdoor temperature that are
likely to occur before the next oil change.

Engine
1-02 Oil cleaner
Cleaning
Old design
Oil cleaner, old design. After these instructions,
there are also instructions corresponding to the
new design. Identify the design of the vehicle's
oil cleaner, and follow the corresponding
instructions.
1 Clean the cover. Unscrew the nut and

remove the cover.
100263
2 Lift out the rotor and loosen the nut on the
rotor bowl three turns.
x3
01 1286
3 If the nut is jammed:

Clamp the nut (but on no account the
rotor) in a vice and turn the rotor three turns x3
by hand or with a screwdriver.
01 1287

Engine
4 Tap the nut lightly with your hand or a

plastic hammer, to detach the rotor bowl
from the bottom plate.
01 1288
5 Unscrew the nut and remove the rotor bowl.
Prize carefully to detach the strainer from
the bottom plate.
01 1289
6 Scrape off any deposits inside the rotor

bowl. If the deposits are thicker than
26 mm, the oil cleaner should be serviced
more often.
01 1290

Engine
7 Wash all parts in diesel oil.
! WARNING!
Wear protective gloves.
01 1291
8 Fit the O-ring in the rotor bowl. The O-ring
must not be damaged.
01 1292
9 Reassemble the rotor.
01 1293

Engine
10 Tighten the rotor nut firmly by hand.
01 1294
11 Refit the rotor.
Make sure that it spins easily.
01 1419
12 Check that the O-ring in the bowl is

undamaged.
Refit the bowl and tighten the lock nut to
10 Nm.
100264

Engine
Newer version
Oil cleaner, new design. Identify the design of
the vehicle's oil cleaner, and follow the
corresponding instructions.
There should be a certain amount of deposited
dirt apparent in the rotor bowl during cleaning
of the oil cleaner. If this is not the case, it
indicates that the rotor is not spinning. The
cause must be established immediately.
If the dirt deposit exceeds 28 mm at the
recommended intervals, the rotor bowl should
be cleaned more often
1 Clean the cover. Undo the nut securing the

outer lid.
2 Let the oil run out from the rotor.
3 Lift out the rotor. Wipe off the outside.
Undo the rotor nut and screw it about one
and a half turns to protect the bearing. x 1.5 133 315

Engine
4 If the rotor nut is difficult to get loose, turn

the rotor upside down and fasten the rotor
nut in a vice. Turn the rotor one and a half
turns counterclockwise by hand or use an
M20 nut as illustrated. M20
x 1.5
IMPORTANT! The rotor must not be put in a

vice. Never strike the rotor bowl. This may
cause damage resulting in imbalance.
133 316
5 Remove the rotor bowl by grasping the rotor
in both hands and tapping the rotor nut
against the table. Never strike the rotor
directly as this may damage its bearings.

Engine
6 Remove the strainer from the rotor bowl. If

the strainer has seized, pry carefully with a
screwdriver between the rotor bowl and the
strainer.
133 317
7 Scrape away the deposits inside the bowl
with a knife.
8 Wash the parts.

9 Inspect the two nozzles on the rotor. Make
sure they are not blocked or damaged.
Renew any damaged nozzles.
10 Make sure the bearings are not damaged.
127 878

Engine
11 Fit the strainer to the rotor.

12 Fit a new O-ring by sliding it over the
strainer.
13 Refit the rotor bowl. Make sure that the
O-ring sits correctly on the inside.
14 Refit the rotor nut and tighten by hand.
127 881
15 Make sure the shaft is not loose. Secure with
locking compound 561 200 if it is loose.
First clean thoroughly using a suitable
solvent. Tighten the rotor shaft using socket
99 520. Tightening torque 34 Nm.
16 Refit the rotor and spin it by hand to make
sure it rotates easily.
127 882

Engine
17 Inspect the O-ring on the oil cleaner housing

lid and fit it. Torque tighten the lock nut to
15 Nm.
Functional inspection
A functional inspection need only be carried out
if the lubricating oil cleaner is suspected not to
work properly, e. g. if there is an abnormally
small amount of deposit in the oil cleaner in
relation to the distance travelled.
The rotor rotates very fast and should continue
to turn when the engine has stopped.
1 Run the engine until it is warm.
100265
2 Stop the engine and listen for the sound

from the rotor. Use your hand to feel if the
filter housing is vibrating.
3 If the filter housing is not vibrating,
dismantle and check the oil cleaner.

Engine
1-03 Renewal of insert filter

1 Unscrew the filter cover with socket
588 475.
2 The filter housing will drain automatically
once the filter has been removed.
3 Renew the O-ring in the cover. Lubricate the
O-ring with engine oil.
IMPORTANT! Fit the filter insert into the cover

before placing it in the filter housing or the filter
insert might be damaged.
4 Fit the filter insert and the cover in the filter

housing and tighten the cover to 25 Nm +/-
5 Nm.

Engine
1-04 Crankcase ventilation
Renewing the filter

Clean the filter housing and renew the filter.
116 826
1-05 Checking the poly-V-belt
IMPORTANT! Do not change the direction of

rotation of the poly-V-belt when it is refitted.
105 874
Small cracks in the poly-V-belt can be accepted.

Engine
• Loosen the poly-V-belt from the pulleys,

but leave it around the fan shaft, so that the
direction of rotation of the poly-V-belt is
not changed.
• Check the poly-V-belt carefully. If the
poly-V-belt has one or more cracks, renew
it.
105 875
If there are large cracks or if pieces of the
poly-V-belt are missing, renew it.
• Also check wear on the poly-V-belt.
112 931
The poly-V-belt shows signs of wear. Can be
refitted.
112 932
The poly-V-belt is worn down to the chord. The

poly-V-belt must be renewed.

Engine
1-06 Checking belt tension
Automatic belt tensioner

The belt tensioner must not be adjusted, opened,
repaired or modified in any way. If the belt
tensioner does not provide sufficient tensioning
of the poly-V-belt, it must be renewed.
Noise in the belt drive

Check the belt tensioner by slowly pressing it
from the belt until it stops. Then, slowly bring
the belt tensioner back to the initial position.
Repeat 2-3 times. Jamming or jerking of the belt
tensioner is not permissible.
Measurement
Recommended belt tension for FO belts

New belt 370 Nm
Used belt 310 Nm
New V-belts need a higher tension since they are

stiffer.

Engine
1-07 Valve clearances and PDE unit injectors, 9 litre

engine with 5 cylinders
Specifications
Unit injector measurement (cold engine) 66.9+/-0.1 mm
Valve clearance, intake valve 0.45 mm
Valve clearance, exhaust valve 0.70 mm
Tightening torques
Adjusting screw lock nut on rocker arm for unit injector 39 Nm
Adjusting screw lock nut on rocker arm for valves 35 Nm
Note: Check and adjust the valve clearance and

unit injectors with the engine cold.

Engine
Order of adjustment
Adjustment applies to a 9 litre engine with
5 cylinders.
In order for the adjusting to be carried out on the
correct revolution, proceed as follows:
1 Rotate the flywheel so that the 72° mark on
the flywheel can be seen in the lower
window of the flywheel housing whilst
valve overlap occurs on cylinder 5.
2 Then turn the flywheel clockwise so that it
passes TDC Down (0°) by about 20° and
then turn it anticlockwise until
TDC Down (0°) is visible in the bottom
window on the flywheel housing. The
reason for turning past TDC down (0°) and
then back is to counteract any play in the
gears.
You are now on the first revolution and can
adjust the valves and unit injectors according to
the following table.
3 Rotate the flywheel anti-clockwise using
tool 99 309 so that the mark on the flywheel
is visible in the lower window of the
flywheel housing.

Engine
Mark on Revolution Adjust unit Adjust intake and Valve overlap on

flywheel injector rocker exhaust valves on cylinder
(degrees) arm on cylinder
cylinder
1 2 1
TDC Down 0
2 1
144 1 4 2
504 2 2
288 1 5 4
648 2 4
72 1 5
432 2 3 5
216 1 3
576 2 1 3
144 216
72 288
TDC Down *
134 537
Flywheel seen from the rear of the engine.

* Direction of rotation when adjusting.
The solid line shows the order to take the angles
on the first round and the broken line the order
for round 2.

Engine
The flywheel is also marked at 240°/600° and

120°/480°; these marks apply to 6 cylinder
engines.
1 Start by rotating the flywheel so that the
mark on the flywheel is visible in the lower
window as illustrated. Never read off the
flywheel mark in the top window - this
reading will be completely wrong.
2 Fit adjusting tool 99 414 with the metal
plate around the unit injector.
! WARNING! 66.9
When the unit injector is checked and

the measurement is outside
66.9+/-0.5 mm, it is necessary to be very
careful when handling this unit injector. 124 856
The spring is pre-tensioned and can

come loose, causing personal injury.
Setting tool 99 414 acts as a gauge with the
measurement 66.9 mm.

Engine
3 When adjusting, loosen the lock nut and

adjust the unit injector with adjusting screw
1. The unit injector is correctly set when the
small piston 2 is level with the flat upper
surface of the tool. Check using a finger. It
is possible to feel differences of less than a
millimetre. The setting dimension is
66.9 +/-0.1 mm.
Refer to tables in Order of adjustment for
unit injectors.
The setting tool piston is above or below the flat The setting tool piston is level with the flat upper
upper surface of the tool. Adjust the unit surface of the tool. The unit injector is correctly
injector. adjusted.
4 Torque tighten the lock nut to 39 Nm after

adjusting.
5 Remove tool 99 414.

Engine
IMPORTANT! Fit the cables so that they face

in the correct direction when fitting them on the
unit injector.
6 Reconnect the cables on the unit injectors.

Their relative position is not important. Use
torque screwdriver 588 179 to tighten the
screws to 2 Nm.
IMPORTANT! Use torque screwdriver 588 179

to avoid the risk of shearing off the screws. The
entire unit injector must be renewed if the
screws shear off.
118 482
7 If the cables to the unit injector are too long,
they can be clamped round the solenoid
valve on the unit injector.
588 179
8 Refit the upper rocker cover and torque
tighten the bolts to 18 Nm.
9 Close the bleeder nipple and tighten the
banjo screw.
10 Fill and bleed the fuel system, refer to
Bleeding the fuel system.
107 675

Engine
1-08 Valve clearances 9, 11 and 12 litre engines with

6 cylinders
Note: Check and adjust on cold engine.
Checking
Check the valve clearance. The clearance should
be:
9 and 11 litre engines: Intake valves 0.45 mm
and exhaust valves 0.80 mm.
DC9, DC11 and 12 litre engines: Intake valves
0.45 mm and exhaust valves 0.70 mm.
Adjusting
The following alternative methods of
adjustment are possible:
99 309
Alternative A:
• Adjust all the valves for each cylinder when
in TDC after the compression stroke. Rotate
the crankshaft 1/3 turn each time with tool
99 309. Adjust the valve clearance in the
same order for injection:
1-5-3-6-2-4 T DC 10
DOWN
101 333

Engine
Alternative B:
1 Put cylinder 1 at exact TDC after the
compression stroke. Adjust the following
valves.
cyl 1 Intake and exhaust

cyl 2 Intake
cyl 3 Exhaust
1 2 3 4 5 6
01 1393
cyl 4 Intake
cyl 5 Exhaust
2 Turn the crankshaft exactly one revolution.

Adjust the following valves.
cyl 2 Exhaust
cyl 3 Intake
1 2 3 4 5 6
cyl 4 Exhaust
01 1394
cyl 5 Intake
cyl 6 Intake and exhaust A 12 litre engine is illustrated
Ο Intake valve
⊗ Exhaust valve

Engine
1-09 Valve clearances 14 and 16 litre engines
Checking
Check the valve clearance. The clearance should
be:
14 litre engine: Intake valves 0.45 mm and
exhaust valves 0.80 mm.
16 litre engine: Intake valves 0.45 mm and
exhaust valves 0.70 mm.
The following two alternative methods of
adjustment are possible.
01_1182
Cylinder numbering
14 litre engine
The following alternative methods of
adjustment are possible:
Alternative A:
• Adjust all valves for each cylinder. Start 99 309
with cylinder 1 at TDC after the
compression stroke. Rotate the crankshaft
1/4 turn each time with tool 99 309. Adjust
the valves in the injection order:
1-5-4-2-6-3-7-8
101379

Engine
Alternative B:
1 Rotate the crankshaft in the direction of
rotation until the piston in cylinder 1 is at
20° after TDC in the combustion stroke.
There is a mark ⊥ at this degree.
2 Adjust the following valves:
Right-hand side
cyl 1 Exhaust and intake

cyl 2 Exhaust
cyl 4 Exhaust
Left-hand side

cyl 7 Intake
cyl 8 Intake
3 Turn the crankshaft exactly one revolution

in the direction of rotation. Then the piston
in cylinder 1 is at 20° after TDC in the
intake stroke. Adjust the following valves:
Right-hand side
Ο Intake valve
cyl 2 Intake
⊗ Exhaust valve
cyl 3 Exhaust and intake
cyl 4 Intake
Left-hand side

cyl 7 Exhaust
cyl 8 Exhaust
Torque tighten the valve lock nut to 35 Nm after

adjusting.

Engine
16 litre engine
Rotate the flywheel using tool 99 309 so that the
mark on the flywheel is visible in the bottom
window according to the table below.
Mark on flywheel Valve change on Adjust intake Adjust exhaust

(degrees) cylinder valve on cylinder valve on cylinder
TDC Down 0° 6 7 and 8 4 and 5
TDC Up 180° 7 1 and 5 2 and 6
TDC Down 360° 1 2 and 4 3 and 7
TDC Up 540° 4 3 and 6 1 and 8
It is a good idea to mark the rocker arm with a

pen after adjustment to keep track of what has
already been adjusted.
Torque tighten the valve lock nut to 35 Nm after
adjusting.
5 1
6 2
7 3
8 4
106 007
Cylinder numbering

Engine
1-10 Scania PDE unit injectors (6 or 8 cylinders)
Checking and adjusting spring height
4 Clean the rocker cover and around the

rocker cover.
5 Remove the rocker cover.
! WARNING! UP TDC
Always place axle stands under the VALVE 3.4

frame when working underneath
vehicles with air suspension. Empty the VALVE 2.5
air bellows. If the vehicle has a tag axle,

it should be lowered.
6 Rotate the flywheel using tool 99 309 so 99 309

that the mark on the flywheel is visible in
the bottom window according to the table
below. Never read off the flywheel mark in
110 578
the top window - this reading will be
completely wrong.
6 cylinder engine
Mark on flywheel (degrees) Valve overlap on Adjust unit injector rocker arm on
cylinder cylinder
TDC Down 0° 1 2
Valve 2, 5,120° 5 4
Valve 3, 4,240° 3 1
TDC Down 0° 6 5
Valve 2, 5,120° 2 3
Valve 3, 4,240° 4 6

Engine
8 cylinder engine
Mark on flywheel (degrees) Valve overlap on Adjust unit injector rocker arm on
cylinder cylinder
TDC Down 0° 6 4 and 5
TDC Up 180° 7 2 and 6
TDC Down 360° 1 3 and 7
TDC Up 540° 4 1 and 8
7 Fit adjusting tool 99 414 with the metal

plate around the unit injector. Check
dimension 66.9 +/- 0.5 mm
66.9
124 856
Setting tool 99 414 acts as a gauge with the

measurement 66.9 mm.

Engine
8 When adjusting, loosen the lock nut and

adjust the unit injector with adjusting screw
1. The unit injector is correctly set when the
small piston 2 is level with the flat upper
surface of the tool. Check using a finger. It
is possible to feel differences of less than a
millimetre. The setting dimension is
66.9 +/-0.1 mm.
The setting tool piston is level with the flat upper

The setting tool piston is above or below the flat
upper surface of the tool. Adjust the unit surface of the tool. The unit injector is correctly
injector. adjusted.
9 Torque tighten the adjusting screw lock nut

to 39 Nm.

Engine
1-11 Scania HPI unit injectors
Note: Adjust on cold engine.
Adjusting OBL (Outer Base Load) preload
Adjustment is carried out at the same time as

checking or adjusting valve clearances.
1 Clean the rocker cover and around the
rocker cover.
2 Remove the rocker cover.
UP TDC
! WARNING!
VALVE 3.4
Always place axle stands under the
frame when working underneath VALVE 2.5
vehicles with air suspension. Empty the

air bellows. If the vehicle has a tag axle,
it should be lowered.
99 309
3 Rotate the flywheel using tool 99 309 so
that the mark on the flywheel is visible in
the bottom window according to the table
110 578
below. Never read off the flywheel mark in
the top window - this reading will be
completely wrong.
Mark on flywheel (degrees) Valve overlap on Adjust rocker arm on cylinder

cylinder (OBL)
TDC Down 0° 6 4
120°/480° 2 1
240°/600° 4 5
TDC Down 360° 1 3
120°/480° 5 6
240°/600° 3 2

Engine
4 Loosen the lock nut and the adjusting screw.

5 Lubricate the adjusting screw, tighten to
6 Nm and angle tighten a further 60°.
Tighten the lock nut to 39 Nm.

Engine
1-12 Air cleaner

Air is drawn through the aperture in the side of
the air cleaner. It is filtered through the paper
filter and is drawn through the upper aperture to
the turbocharger.
There is a rubber valve underneath the air
cleaner that acts as a drain. Water that enters the
air cleaner is collected at this point. The rubber
valve opens when the pressure exerted by the
water is greater than the pressure in the air
cleaner.
01_1298
The right-hand bumper cover must be removed
in order to renew the filter. It is fastened with
three bolts. This does not apply to vehicles with
steel bumpers.
Loosen the clips that hold the filter cover in 00_1655
place. 00_1531
Renew the filter element.
Note: Do not forget to reset the vacuum

indicator, see Vacuum indicator.
00 1532

Engine
Vacuum indicator
P/R vehicles: The vacuum indicator is located
inside the right-hand boarding step.
T vehicles: The vacuum indicator is located

inside the right-hand service step.
Engine output will be affected if the filter admits
insufficient air to the engine. Other related
effects are increases in fuel consumption and the
00_1533
amount of carbon particles in the exhaust, both
of which are caused by the reduced output being
compensated for by increased throttle. There is
also an increased risk of damage to the
turbocharger.
The vacuum indicator has two windows, the

smaller of which indicates the need for a new
filter by changing colour; the larger window is
graduated. When the vacuum indicator shows
5.0 kPa, the filter element should be changed.
Note: Reset the vacuum indicator by pressing

the centre as illustrated.
00_1534

Engine
1-13 Intake manifold
Retightening straps
Retighten the straps on the air intake pipe
between the air cleaner and the turbocharger.
The straps, two on each air intake pipe, must be
tightened by hand to 4.5+/-1 Nm.
Use torque screwdriver 588 179.
109 517
The illustration shows the straps on a 12-litre
engine

Cooling system
2 Cooling system
2-01 Coolant
The coolant can normally be used as long as it is
pure and clear. ! WARNING!
Hot coolant can cause burns. Ethylene

Use only Scania or Scania approved antifreeze glycol is highly dangerous if ingested
glycol for frost protection; refer to Workshop and can prove fatal. It has a toxic effect
Manual 00:03-09 Fuel, lubricants and fluids. on the skin, particularly when the
Different approved products may be mixed, but coolant is hot. Wear protective gloves.
in order to obtain optimal corrosion protection, Scania corrosion inhibitor is dangerous
products from the same manufacturer and of the if imbibed.
same type should be used. The protection level
will correspond to that of the product with the
lowest value, regardless of any amount of other
anti-freeze products added.
Anti-freeze agents approved by Scania are
designed for Scania engines. Scania can largely
control and influence the contents of anti-freeze
agents with Scania part numbers.
1 Measure the level of glycol anti-freeze

(ethylene glycol) with Coolant and battery
(70%)
(66%)
-48 (61%)
(61%)
-42 (58%)
tester 588 227. 1.400
1.350
-48
-42
(57%)
(53%)
-36
-30
(54%)
(50%)
-37 (50%)
-27 (47%)
GOOD
-33 (47%)
-24 (44%)
1.300 -30 (45%)
-27 (42%) -21 (41%)
-24 (40%)
1.250 -18 (38%)
-21 (36%)
FAIR
(33%)
-15 (34%)
-18
1.200
(29%) -12 (30%)
-15
-12 (25%)
1.150 -9 (24%)
RECHARGE
-9 (20%)
-6 (18%)
1.100
-6 (15%)
BATTERY
CHARGE
-3 (9%)
SPECIFIC -3 (9%)
GRAVITY
ETHYLENE PROPYLENE
GLYKOL GLYKOL
+0 (0%) +0 (0%)
C
FREEZE POINT
% GLUKOLE BY VOLYME
121 091

Cooling system
Ethylene glycol concentration table

If the glycol content is below 40%-by volume,
the corrosion protection is not sufficient.
Freezing point °C -6 -9 -12 -18 -21 -24 -30 -37 Cooling system
Ethylene glycol 15 20 25 33 36 40 45 50 volume in litres
(% by vol)
Ethylene glycol (litres) 5 6 8 9 11 12 14 15 30
6 7 9 11 13 14 16 18 35
6 8 10 12 14 16 18 20 40
7 9 12 14 16 18 21 23 45
8 10 13 15 18 20 23 25 50
9 11 14 17 20 22 25 28 55
9 12 15 18 21 24 27 30 60
10 13 17 20 23 26 30 33 65
11 14 18 21 25 28 32 35 70
12 15 19 23 27 30 34 38 75
12 16 20 24 28 32 36 40 80
13 17 22 26 30 34 39 43 85
14 18 23 27 32 36 41 45 90
15 19 24 29 34 38 43 48 95
15 20 25 30 35 40 45 50 100
16 21 27 31 37 42 48 53 105
17 22 28 32 40 44 50 55 110
18 23 29 34 41 46 52 58 115
18 24 30 35 42 48 54 60 120
19 25 32 37 44 50 57 63 125

Cooling system
2-02 Renewing the coolant filter

Tools
Filter tongs 587 025
1 Close the drain tap and renew the coolant

filter.
2 Open the drain tap.
02_0350
02_0351
If the vehicle is fitted with a coolant filter, the
filter must be renewed at every L-inspection in
order to uphold the functionality of the filter. Valve open Closed tap
Scania coolant filters no longer contain

corrosion inhibitor.
As of August 2000 the coolant filter has been
discontinued and is therefore not fitted to
vehicles manufactured after that date.
2-03 Measuring corrosion inhibitor
IMPORTANT! For cooling systems with

corrosion inhibitor only, without glycol.
! WARNING!
Hot coolant can cause burns. Wear

protective gloves. A mixture of different
Tools corrosion inhibitors could result in
accumulation of sludge and poorer
Corrosion inhibitor gauge 588 572
protection against corrosion. Scania
corrosion inhibitor is dangerous if
Refer to Workshop Manual Main Group 2 for imbibed.
calibrating the corrosion inhibitor gauge.

Cooling system
IMPORTANT! Note the obtained values in

order to check for correct corrosion protection in
the corrosion inhibitor table.
1 Extract some coolant from the expansion

tank.
2 Spray some coolant into a cup or equivalent.

3 Allow the coolant to cool down to 40°C.
122 122
4 Fit corrosion inhibitor gauge 588 572. It has
to be switched on for at least 5 minutes
before measuring.
OFF
ON
122 114
5 Remove the protection cover from the probe

electrodes on corrosion inhibitor gauge
588 572.
122 124

Cooling system
6 Clean the probe electrodes with distilled

water and denatured alcohol. Wipe off the
electrodes.
122 116
7 When checking different coolants, rinse the
probe electrodes in distilled water and
denatured alcohol before the next
measurement.
8 Place corrosion inhibitor gauge 588 572 in
the vertical container.
122 117
9 Place the container or equivalent with

coolant under the corrosion inhibitor gauge
588 572 and dip the probe electrodes
completely in the coolant.
122 118

Cooling system
10 Wait a couple of minutes for the value in the

display of the corrosion inhibitor gauge
588 572 to stabilise.
11 Read and note the value.
122 467
12 Check the level of corrosion inhibitor in the
Corrosion inhibitor diagram.
13 The level should be 8-12% by volume. The
standard value should be 10% by volume.
14 After use the corrosion inhibitor gauge
588 572 should be cleaned in distilled water
and denatured alcohol.
15 Do not forget to fit the protection cover and
switch off the corrosion inhibitor gauge
588 572.

Cooling system
Corrosion inhibitor diagram
After measuring the conductivity value with

the corrosion inhibitor gauge 588 572, check
the conductivity value in mS against the
corrosion protection in % by volume.
The corrosion inhibitor should be 8-12% by
volume when checked.
14,0
13,0
12,0
11,0
10,0
9,0
8,0
7,0
6,0
5,0
4,0
3,0
2,0
1,0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
122 657
Min Max.

Cooling system
Corrosion inhibitor concentration table
Note: Scania corrosion inhibitor with a level of

10% by volume is equivalent to 40% by
volume of Scania glycol anti-freeze.
Corrosion inhibitor 0 2 4 6 8 10 Cooling system

(% by vol) volume in litres.
Corrosion inhibitor. (litres) 0 0.6 1.2 1.8 2.4 3.0 30
0 0.7 1.4 2.1 2.8 3.5 35
0 0.8 1.6 2.4 3.2 4.0 40
0 0.9 1.8 2.7 3.6 4.5 45
0 1.0 2.0 3.0 4.0 5.0 50
0 1.1 2.2 3.3 4.4 5.5 55
0 1.2 2.4 3.6 4.8 6.0 60
0 1.3 2.6 3.9 5.2 6.5 65
0 1.4 2.8 4.2 5.6 7.0 70
0 1.5 3.0 4.5 6.0 7.5 75
0 1.6 3.2 4.8 6.4 8.0 80
0 1.7 3.4 5.1 6.8 8.5 85
0 1.8 3.6 5.4 7.2 9.0 90
0 1.9 3.8 5.7 7.6 9.5 95
0 2.0 4.0 6.0 8.0 10.0 100
0 2.1 4.2 6.3 8.4 10.5 105
0 2.2 4.4 6.6 8.8 11.0 110
0 2.3 4.6 6.9 9.2 11.5 115
0 2.4 4.8 7.2 9.6 12.0 120
0 2.5 5.0 7.5 10.0 12.5 125
0 2.6 5.2 7.8 10.4 13.0 130

Cooling system
Topping up with coolant
Note: Do not top up with water only.
In countries where the temperature never

drops below 0°C:
The coolant must consist of 1/10 corrosion
inhibitor and 9/10 freshwater without visible
impurities.
Other countries:
The coolant must contain 30-60% glycol and
freshwater without visible impurities.

Fuel system
3 Fuel and exhaust systems
3-01 Renewal of fuel filter, bleeding

IMPORTANT! Engines with unit injectors must

be fitted with fuel filters marked HIGH
PERFORMANCE.
X
X X
X X
XX X
X
HIGH X
PERFORMANCE
HIGH PERFORMANCE
114 614
1 Clean the fuel filter and the filter retainer.
03_0808
2 Unscrew the fuel filter.

Use filter tongs, e.g. 587 025.
03_0809

Fuel system
3 Lubricate the O-ring of the fuel filter and

screw the new fuel filter into place by hand
until the gasket comes into contact with the
retainer. Tighten a further half turn. Bleed
the fuel system as described below.
03_0810
Engines with injection pump
Bleeding
1 Turn the starter key to the drive position.
Undo the banjo screw on top of the fuel
filter a few turns. Place a suitable receptacle
under the fuel filter. Pump with the hand
pump until clean fuel appears that is free
03_0806
from air bubbles. Tighten the banjo screw.
2 Open the overflow valve on the fuel valve a

few turns. Pump with the hand pump until
the fuel coming out of the open overflow
valve is free of air bubbles. 03 0811
3 Close the overflow valve 1. Keep pumping

for a while 2. The air in the injection pump 1
will then be pushed out through the
overflow valve. 2
4 Start the engine and check for leaks.
03_0812

Fuel system
Renewal of insert filter on engines with PDE
1 Open the bleeder nipple on the fuel filter to

release any remaining pressure.
588 475.
once the filter insert has been removed.
4 Wipe the fuel filter base clean.
5 Renew the O-ring in the cover. Lubricate the
O-ring with O-ring grease 1 402 039.
IMPORTANT! Fit the filter insert into the cover

before placing it in the filter housing or the filter
insert might be damaged.
6 Fit the filter insert and the cover in the filter

housing and tighten the cover to
25 Nm+/-5 Nm. Bleed the fuel system as
described below.

Fuel system
Bleeding of DC16 engines with PDE
1 Attach a clear plastic hose to the bleeder

nipple on the filter housing.
2 Open the bleeder nipple and pump with the

hand pump until fuel comes out of the hose.
3 Close the bleed nipple and remove the hose.
4 Continue pumping by hand until a
resistance is felt, which will be after
approximately 20 pump strokes.
116 268

Fuel system
Bleeding of DC11 and DC12 engines with PDE

nipple at the front of the fuel manifold.
• If the system is completely empty, it will
take approximately 250 strokes.
• After renewing the fuel filter, it will take
approximately 170 strokes.
• Approximately 150 strokes are required
to bleed the fuel manifold.
3 Pump an additional 20 strokes to remove the
116 545
air.
4 Close the bleeder nipple and remove the

hose. Pump with the hand pump until the
pressure relief valve opens, approximately
20 strokes.

Fuel system
Bleeding of 9 litre engines, 5 cylinders, with PDE

nipple on the fuel filter housing.
When the fuel system is empty, it is
necessary to pump approximately 100
strokes in order to draw fuel up to the
bleeder nipple.
3 Pump until fuel without air bubbles comes
out, approximately 20 strokes.
5 Transfer the plastic hose to the fuel
manifold bleeder nipple.
6 Open the fuel manifold ventilating valve.
7 Pump with the hand pump until fuel without
air bubbles comes out, approximately
135208
50 strokes.
8 Close the bleeder nipple on the fuel
manifold and remove the plastic hose.
9 Pump approximately 20 strokes with the
hand pump until the overflow valve opens.
A hissing sound should be heard.
10 Start the engine. The engine should be easy
to start.

Fuel system
Renewal of insert filter on engines with HPI
1 Open the bleeder nipple on the filter to

release any remaining pressure. It may be
difficult to unscrew the filter cover if the
system pressure has not fallen enough.
Note: Fuel will come out of the bleeder nipple

and this should be collected in a suitable
manner.
25 Nm
588 475.
(slowly) once the filter element has been
removed.
Note: If the drain is not working, the remaining

fuel should be removed.
4 Unscrew the overflow valve and blow the

strainer in the filter housing clean.
5 Also wipe the bottom of the filter housing.
6 Fit a new O-ring on the cover. Lubricate the
O-ring with O-ring grease.
B 119 290
IMPORTANT! Fit the filter element into the
cover before placing it in the housing or the
filter element might be damaged.
7 Press down the filter element into the

housing with the cover. Screw on the filter
cover firmly with sleeve 588 475.
Tightening torque 25 Nm.
8 Bleed the fuel system

Fuel system
Bleeding of engines with HPI

nipple on the fuel filter housing.
IMPORTANT! Do not crank with the starter

motor for longer than 30 seconds at a time.
2 Open the bleeder nipple fully and crank

with the starter motor until the fuel system
is purged free of air.
Run until all the air has been removed and
there is a good flow of fuel.

B 119 292

Fuel system
Water separating fuel filter

A fuel filter with water separation is available as
an accessory. It can be used instead of the usual
type of fuel filter.
The same interval between renewal applies as
for an ordinary fuel filter.
Drain at every inspection.
105 915
32: Drain valve
Auxiliary water separating fuel filter
Some vehicles are equipped with an additional

water separating fuel filter attached to the
chassis.
Note: Close the drain tap when renewing the

additional water separating fuel filter.
The same interval between renewal applies as

for an ordinary fuel filter.
Drain at every inspection.
109 700
1 Shut-off cock
2 32: Drain valve

Fuel system
3-02 Gas engine
! WARNING!
Beware of the risk of fire. Make sure

there is nothing glowing and there are
no sparks, naked flames or similar in the
vicinity when working on the gas
system.
IMPORTANT! For all work on the gas system,

the specific laws and regulations of the country
concerned regarding gas and the handling of gas
equipment must be followed.
The integrity of the gas system

Check the gas system integrity in the direction
of flow with leak detection spray or soapy water.
Checking spark plugs

Check the electrode gap.
Correct electrode gap aids the engine
combustion and reduces the risk of flashover.
Distance between the electrodes should be
0,35-0,50 mm.
Tightening torque 30 +/-5 Nm.

Fuel system
Checking lambda at idle speed

Test equipment
Tool no Description
588 460 Lambda sensor
588 462 Cable harness
588 461 Test control unit
588 094 Multimeter (included in kit 588 093)
IMPORTANT! The engine temperature must be

around 80°C when checking and adjusting the
lambda.
1 Run the engine until it reaches normal

operating temperature.
2 Check that the idling speed is approx.
550 rpm. Adjust idling speed as required by
turning the idling screw 1.
3 Take a sensor voltage reading with the

multimeter. It should read between 1.60 V
and 1.90 V at 550 rpm.
4 Adjust the lambda value if necessary by
turning the mixture screw 1 on the gas
mixer. If the correct lambda value cannot be
set, take off the outer diaphragm of the gas
mixer and remove or add shims on the gas
valve.

Fuel system
Checking lambda with the engine under load.
1 Attach the test equipment as described in

"Fitting the test equipment".
2 Set restrictor 1 on the gas mixer inlet half
way between the L and R marks if the
engine has not been adjusted before.
3 Measure at wide open throttle acceleration

in a high gear from approx. 1000 r/min till
2000 r/min. Read the sensor voltage at
200 rpm intervals from 1000 rpm.
4 Make a copy of the diagram and plot the
readings. The existing curves indicate
minimum and maximum values. The
thin-line curves indicate limits at 150 bar
gas pressure and the bold ones at 50 bar gas
pressure.
The X axis shows the engine speed in rpm

The Y axis shows the sensor voltage in volts

Fuel system
5 Adjust the gas pressure if the sensor voltage

is too high or too low across the whole
engine speed range.
6 Unscrew the plugs and adjust the gas
pressure with the set screws on the low
pressure regulators. Adjust both regulators
the same amount. Turning clockwise will
increase the gas pressure and lower the
sensor voltage. Do not screw in the set
screw more than 16 turns from fully
unscrewed position.
Note: Screwing in the set screw more than 16

turns will cause the spring seat to come loose
from the screw.
IMPORTANT! The plugs must be refitted in the

low pressure regulators before testing. Leaks
can affect the lambda value.
7 If the adjustment range of the screw is

insufficient, the regulator spring should be
renewed.

Scania particle filter
3-03 Scania particle filter

Cleaning the filter unit
IMPORTANT! Handle the filter unit with care.

The filter unit consists of a ceramic material and
is impact and shock sensitive.
1 Remove the side cover and place a jack with

a large plate under the filter unit.
2 Mark the direction in which the filter is
installed.
Note: The filter unit should be turned 180

degrees when fitted.
121 252
! WARNING!
A face mask and protective goggles

must be worn when cleaning the particle
filter.
The particle filter is very hot.
121 253
3 Remove the upper V-clamp holding the

filter unit in place.
4 Lower and remove the filter unit. Remove
the lower V-clamp and the exhaust pipe
bracket screws.

Scania particle filter
5 Check for traces of soot on the filter unit

outlet side. If this is the case, the filter unit
probably is damaged and must be changed.
6 Clean the filter unit as follows:
7 Carefully shake the filter unit to remove all
loose ash deposits from the filter unit cells.
8 Using an industrial vacuum cleaner,
remove all ash deposits and soot from
visible surfaces both on the catalytic
converter and the filter unit.
9 Inspect the surfaces on the catalytic
converter and filter unit to check for:
- Cracks in the surface or pitting.
- That the ceramic filter is firmly seated in
the outer container.
10 If no defects can be found on the filter unit,

turn it 180 degrees and fit it. Refer to the
illustration.
11 Connect an extractor to the exhaust pipe.
121 254
Start the engine and rev it a couple of
times. This prevents any ash residues from
penetrating into the workshop after the
filter unit has been turned.
Discarded particle filters and filter units, and
ash deposits and soot from the filter must be
disposed of according to local legislation.

Clutch
4 Clutch
4-01 Fluid level in clutch

control
Fluid grade: SAE J 1703 (D.O.T. 3/4 Brake
Fluid).
Check that the fluid level is between the marks
on the reservoir.
100669
WARNING!
The fluid is harmful if ingested. Avoid

contact with the skin. Wear protective
gloves and goggles.

Clutch
4-02 Renewing the clutch fluid
Change the clutch fluid by bleeding the clutch

hydraulic system. The work description below
is for vehicles with a bleeder nipple.
For vehicles without a bleeder nipple and for
bleeding without replenishing equipment, refer
to Workshop Manual main group 04, Clutch
and clutch control, function and work
descriptions.
Bleeding using replenishing equipment
587 949
! WARNING!
Wear protective goggles. Hydraulic

fluid is corrosive and can cause Replenishing equipment connected to the
permanent eye damage. hydraulic fluid reservoir.
IMPORTANT! Use new hydraulic fluid of the

type SAE J 1703 D.O.T: 3-4 Brake Fluid.
1 Fill the reservoir of the replenishing

equipment with hydraulic fluid. The
reservoir volume is 5 litres.
2 Connect the replenishing equipment
according to the illustrations and connect a
supply of compressed air.
Bleeding container of replenishing equipment
587 949 connected to bleeder nipple 1 at the
gearbox.

Clutch
3 Fill and bleed the hydraulic system by

opening bleeder nipple 1 on the gearbox.
Repeat the bleeding until all the air has been
removed and only pure hydraulic fluid
flows from the bleeder nipple. The
hydraulic system volume is approx.
0.5 litres.
IMPORTANT! Ensure that the hydraulic fluid

reservoir does not become empty during
bleeding.
4-03 Checking clutch wear
Use gauge 99 315, which indicates the

minimum dimension of the clutch lining.
A new disc is 10 mm thick. A worn disc is 7 mm

thick.
Remove the sound proofing cover.
Remove the protection cover over the inspection
opening on the bottom of the flywheel housing.
Fit the gauge 99 315 and make sure the lining is
more than 7 mm thick.
It may be difficult to reach the disc with the
gauge in some cases. If so, turn the crankshaft
using turning tool 99 309.
The same measurement method is used for the
new clutch with external slave cylinder.
04 0464
99 315

Torque converter
4-04 Torque converter
Checking the oil level

1 Start the engine and run it at idle speed with
the gearbox in neutral.
2 Check the oil level with the dipstick. The
dipstick is behind the cab on P/R vehicles or
in the engine compartment on T vehicles.
Oil change and filter renewal

The drain plugs in both the filter housing and the
torque converter cover must be removed when
changing oil.

Drain plug for filter housing
1 Rotate the flywheel with the tool 99 309 to

access the drain plug in the torque converter
cover through the opening in the flywheel
housing.
2 Undo the cover on the bottom of the
flywheel housing so that the oil can run out.
3 Remove the drain plug (10 mm internal
hexagon) on the bottom of the filter housing
and allow the fluid to run out.
104 903
Drain plug for torque converter cover

Torque converter
4 Remove the drain plug (6 mm hexagon)

from the torque converter cover and allow
the oil to run out. Take care not to drop the
drain plug between the torque converter and
the flywheel housing.
5 Check the O-ring on the torque converter
drain plug. Renew if necessary. Refit the
drain plug. Tightening torque 20 Nm.
6 Wipe the cover and refit it to the bottom of
the flywheel housing.
7 Undo the bolts and remove the filter

housing.
8 Clean the filter housing and the magnet, see
arrow.
9 Fit a new filter and gasket.
10 Refit the filter housing and the drain plug.
Use new gaskets. Tightening torque 50 Nm.
11 Fill with approx. 10 litres oil. If more oil is
filled, it will run out of the vent in the torque
converter.

Torque converter
! WARNING!
Make sure the gearbox is in neutral

before starting the engine.
12 Start the engine and run it at idle speed.

13 Fill with an additional approx. 8 litres of oil
until the oil level is correct on the oil
dipstick.
Oil capacity when changing oil is about
18 litres.
Note: The values are approximate. Check with

oil dipstick. Top up if necessary.
Checking torque limitation

1 Apply the parking brake.
2 Start the engine and run it at idle speed.
3 Engage top gear in low-range and release
the clutch.
4 Accelerate carefully and feel how the
vehicle "strains" against the brake.
5 Depress the clutch pedal slightly but not
enough to declutch. A transition should now
be felt as the torque is limited and the
engine speed drops.

Gearbox
5 Gearbox
5-01 Manual gearbox
1 Remove the noise shield, see illustration.

2 Place a collecting vessel under the gearbox.
Tip: Oil can run onto the exhaust pipe on
vehicles with left-hand mounted exhaust outlet.
Form a piece of metal plate to guide the fluid
past the exhaust pipe and into the collecting
vessel.
100268
! WARNING!

gloves and goggles.
3 Remove the drain plugs and level plugs.

Drain the oil when it is hot.
4 Clean the magnet on the drain plugs and
level plugs.
5 Unscrew the filter.
Note: Check that the old gasket is attached

when the filter is removed.
1 Level plug
2 Drain plug
3 Filter

Gearbox
6 Lubricate the rubber gasket for the new Oil capacities

filter with oil.
Gearbox with oil capacities
7 Screw on the filter by hand until the gasket
rests against the gearbox housing. Tighten GR 801 approx. 9.0
the filter a further half turn. litres
8 Refit the drain plug and tighten to 100 Nm. GR, GRS, GRSH 900, approx. 15.7
Top up the level hole with oil. GRSO 900 litres
9 Refit the level plug and torque tighten to GRS 890, 920 approx. 15.7
100 Nm. litres
GRS 890R, 920R approx. 16.8
litres
GR, GRS 900R, GRSO 900R approx. 16.8
litres
Note: GRS920: The oil cooler, which has an

oil capacity of approx. 2.0 litres, is not drained
when changing transmission oil.
Power take-off
EG610 / 611 / 612 0.5 litres
EG603 / 604 / 606 1.3 litres
EG600 / 601 / 620 / 621 1.7 litres
EK300 / 310 1.1 litres
EK330 / 340 / 630 / 640 2.0 litres
Note: The values are approximate. Check the

oil level and top up as necessary. An oil level
down to 5 mm below the level hole is
acceptable.

Gearbox
5-02 Automatic gearbox
IMPORTANT! A correct fluid level is essential

for the function and service life of the gearbox.
Both too high and too low a fluid level is
harmful for the gearbox.
Checking a cold gearbox

The objective of checking on a cold gearbox is Dipstick location
to determine whether the correct amount of fluid
is in the gearbox so that it can be safely warmed
up. A final check of the fluid level can only be
carried out when the gearbox is warm.
1 Start the engine and run it at idle speed for
about one minute.
! WARNING!
Depress the brake pedal before

proceeding to step 2 below! It is not
enough to only use the parking brake to
keep the vehicle stationary.
2 Select position D and increase the engine

speed to 1000-1500 rpm for 30 seconds.
Then, select position R to remove any air
from the system. Air in the system can give
incorrect results.
3 Then, select neutral N and leave the engine
idling.

Gearbox
! WARNING!
Disengage the power take-off if

applicable so that the rotating shaft is
stationary. The shaft is located close to
the oil dipstick and can cause personal
injury if rotating.
4 Adjust the oil level so that it is in the range

between "COLD FULL" and "COLD
ADD". Fill through the oil filler pipe (or the
dipstick pipe). Drain off fluid if the level is
too high. Dipstick graduation
5 Warm up the gearbox and carry out a final
check of the fluid level as described in
"Checking a warm gearbox".
Checking a warm gearbox

The gearbox must be warm in order to check the
fluid level reliably. The check can be carried out
in two ways: either using the oil dipstick in the
same way as for a cold gearbox check, or
electronically from the driver's seat. The
following description applies to checking the
fluid level electronically.
1 The following conditions must be fulfilled
irrespective of control type:
- The engine must be idling and the vehicle
on flat ground
- The oil temperature must be between 60°C
and 100°C
- The drive mode selector must be in
position N
- The propeller shaft must be stationary
- The fluid level sensor must be free from
faults
Gearbox
2 Lever control, old design: Press once on the

diagnostic switch 1. Use a blunt pen or
similar. If the above requirements are 2
fulfilled, the control unit will start to count
down from 8 to 1 for about two minutes.
3 Lever control, new design: Press once on 1
the Logotype switch 4.
4 Button control: Depress the switches for
102894
shifting up and down 4 once simultaneously.
If all the conditions are fulfilled, the control Older lever control
unit will start to measure the oil level. This 1 Diagnostics switch
takes approximately 2 minutes. The 2 Display
countdown will be terminated if the
conditions are no longer fulfilled and a fault
code will be displayed in the display. Refer
to the table Fault codes when checking oil 1
levels. 2
MODE
3 PERF
108 627
New lever control
1 Diagnostics switch
2 MODE switch
3 Display
4 Logotype switch
1
3 2
PERF
R MODE
D 4
108 626
Button control
1 Diagnostics switch
2 MODE switch
3 Display
4 Up and down shifting

Gearbox
5 After 2 minutes, the display will show one

of the codes in the table. Information codes - oil level
Code Action
6 Cease measuring as follows depending on
the type of drive mode selector: (OL-OK) Oil level correct
o,L,o,K
On the older control, press twice on the
diagnostic switch 1. (LO-01) Fill with one litre oil
o,L,L,o,1
On the new control, press twice on the
Logotype switch 4. (LO-02) Fill with two litres oil
o,L,L,o,2
On the button control, press the N switch
(Neutral). (HI-01) Drain off one litre oil
o,L,H,I,1
(HI-02) Drain off two litres oil
o,L,H,I,2
Codes in brackets apply to vehicles with older

type of control.
Note: The maximum measuring range for the

electronic oil level sensor is shown in the table. Gearbox Oil level
Low High
GA750/751/752 (LO-04) (HI-04)
L,o,4 H,I,4
GA851/852 (LO-06) (HI-07)
L,o,6 H,I,7

type of control.

Gearbox
The drive position selector display indicates one

letter or number at a time. Fault codes when checking oil levels
Code Fault
If none of the information codes are shown in
the display, a fault may have occurred, refer to o,L,0,X Setting time is too short
the table.
(OL-50) Engine speed too low
o,L,-,5,0
(OL-59) Engine speed too high
o,L,-,5,9
(OL-65) The drive position selector is not
o,L,-,6,5 in position N
(OL-70) Oil temperature too low
o,L,-,7,0
(OL-79) Oil temperature too high
o,L,-,7,9
(OL-89) Propeller shaft rotating
o,L,-,8,9
(OL-95) Oil level sensor faulty
o,L,-,9,5

type of control.

Gearbox
Oil change and filter renewal

The oil and filter should be changed while the
gearbox is warm. Warm fluid runs faster and it
will be possible to remove more of it from the
gearbox.
! WARNING!
Beware of hot oil. Wear protective gloves

and goggles.
1 Warm up the gearbox so that the oil

temperature is between 70 and 90°C. Select
position N and turn off the engine.
2 Place a collecting vessel under the gearbox.
Clean around the drain plug and the filter
cover.
3 Unscrew the drain plug on the sump and
allow the fluid to drain. Use a 3/8" square
box spanner.
4 Inspect the condition of the oil. See if there 1 Drain plug (3/8")
are any traces of water, metal particles or 2 Gearbox filter
coolant. Water or coolant in the oil may
indicate that the oil cooler has leaks. If this
is the case, the oil cooler must be renewed.
Metal particles in the oil may indicate
internal damage in the gearbox. If this is the
case, get in touch with a local Allison dealer
before taking any further measures.
5 The gearbox is fitted with two filters.
Remove the screws on the filter covers.
Remove the covers, O-rings, gaskets and
filters.

Gearbox
6 Lubricate and fit O-rings, gaskets and filter

(shorter oil filter for vehicles with
all-wheel drive) to each filter cover.
Position the filters in the oil sump using the
screwholes as guides and press them in by
hand.
IMPORTANT! Do not use the screws to press

the covers in place. Do it by hand, otherwise
the oil sump, filter covers or seals can be
damaged.
7 Fit the screws for the filter covers and

tighten them to 60 Nm.
8 Clean the drain plug and renew the O-ring.
103109
9 Fit the drain plug and O-ring. Tighten the
drain plug to 30 Nm.
10 Fill oil through the oil filler pipe (or the oil
dipstick pipe). The volumes specified in Note: If the oil in a gearbox with retarder is
"Oil capacity when changing fluid and being changed, the fluid volume indicated in the
filter" must be followed when changing oil. table must be increased with approx. 1 litre
11 Check the oil level by checking on a cold

gearbox, refer to the section Checking a Oil capacities when changing fluid and
cold gearbox. Adjust the oil level and then filter
run the gearbox until warm. Make a final
check of the oil level only when the Gearbox Oil capacity
gearbox has reached a temperature GA750/751/752 approx. 20 litres
between 70 and 90°C.
GA750, all wheel approx. 18 litres
drive
GA851/852 approx. 34 litres
GA851/852 on approx. 27 litres
vehicles with
all-wheel-drive

Gearbox
5-03 Opticruise
Oil level in longitudinal stroke
cylinder
Remove the level plug and make sure the oil
reaches up to the level hole.
Top up with automatic transmission fluid if
05 5390
necessary.
5-04 Transfer gearbox

Oil level
Unscrew the oil level plug 4. The oil should
reach up to the level hole.
Note: If the oil level is too high, drive the

vehicle and check again before draining off.
Oil change
1 Place a collecting vessel under the transfer
box.
2 Unscrew the lower 1 and the upper 2 drain
plugs.
3 Drain off oil, refit the plugs and tighten to
80 Nm.
4 Clean the bleeder nipple 5.
5 Unscrew the filler plug 3 and level plug 4.
Fill with oil up to the level hole, approx.
6.5 litres.
Note: All oil must be filled through the filler

hole 3 in order to obtain the correct volume of
oil in the transfer box.
6 Replace the filler and level plugs and

tighten to 80 Nm.

Gearbox
5-05 ZF-transmatic
1 Drain the oil through the three plugs.
125975
125976
2 Remove the filter housing.
125990
3 Remove the bolt holding the filter and

remove the filter.
4 Clean the filter housing.
125974

Gearbox
5 Fit a new gasket, new filter and the cleaned

filter housing.
125978
Note: Make sure that the filter housing is the
right way round.
125990
6 Top up with oil. The oil tank holds 43 litres.
125979

Gearbox
Checking oil level
Note: Check the oil level when the gearbox is

warm.
1 Place the vehicle on the level.
! WARNING!
Place chocks on the wheels and apply

the parking brake to prevent the vehicle
from moving. Danger of personal injury.
2 Start the engine and run it at idling speed

for 2 - 3 minutes. Engage top gear (8H).
Note: Top gear must be engaged in order to

limit the power. The gear must be engaged so
that the oil level will be remain level.
3 Release the clutch.

4 Remove the level plug and check the oil
level through the level hole 1.
5 Top up with more oil if necessary.

6 Engage neutral gear and switch off the
engine.
7 Tighten the level plug.

Propeller shafts
6 Propeller shafts
6-01 Checking propeller
shafts, support bearings
and universal joint cross
1 Check that the propeller shaft and
intermediate shaft are not damaged.
2 Check that there is no play in the universal
joints or the support bearing.
3 Check-tighten the bolts in the support
bearing bracket and make sure the rubber in
the bearing seat is not damaged. Support bearing clamp
Tightening torques
Support bearing clamp: 47 Nm
06 0292
6-02 Checking bearing Bearing cap bolts
retainers
Check-tighten the bearing cap bolts.
Tightening torques
2 1
Bolts, bearing cap P300, 105 Nm
P400, P500
P600 170 Nm
Bolt, end yoke cover 20 Nm
100 952
1 Bearing cap bolts

2 End yoke cover bolt

Front axles
7 Front axles
7-01 Changing oil in axle gear
Driving front axle AMD900
In extremely demanding conditions, we
recommend SAE 75W-140 synthetic oil.
! WARNING!

gloves and goggles.
1 Place a collecting vessel under the axle gear.
105 092
2 Drain the oil when it is hot.
3 Clean the magnet on the drain plugs and Drain plug
level plugs.
4 Refit the drain plug and tighten to 100 Nm.
Top up the level hole with oil.
5 Refit the level plug and torque tighten to
100 Nm.
Oil capacity
RP 731 13.5 litres
RBP 731 17.0 litres
Note: The values are approximate. Check the oil

105 093
level. Top up if necessary. The oil should reach

up to the level hole.
Level plug

Front axles
7-02 Hub reduction gears
Oil change
1 Place a collecting vessel under the hub
reduction gear.
1 2
2 Clean the hub cover.
3 Rotate the hub until the drain plug 3 points
straight down. Refer to illustration
Draining.
4 Remove the drain plugs and filler plugs 2
and 3. Drain the oil.
3
104 909
Draining
1 Marking line
2 Filler plug
3 Drain plug
5 Turn the hub until the cover marking line 1

is in a horizontal position. Refer to
illustration Filling.
6 Add oil through the upper hole 2 until oil
runs out of the lower hole 3.
1 2
7 Replace the drain and filler plugs and
tighten to 10 Nm.
Oil capacity
RH 731 0.8 litres
3
104 910
Filling

Front axles
7-03 Checking front vehicle unit

• It is important that approved axle stands are
used and that they are standing securely
when working on the front axle. 1 2 3
• The air bellows must be empty when

working underneath vehicles with air
suspension.
Check the front vehicle unit as described on the
following pages.
Dust cover and linkage system

Make sure the dust cover, track rod, guide arm,
101 164
4
draglink and draglink arm are not damaged.
1 Steering arm
2 Drag link
3 Drag link arm
4 Track rod
King pin bearings

1 Raise the front axle on supports under the
front springs.
2 Remove the hub cap from the wheel
bearing.
587 571
3 Apply the brakes to prevent play in the

wheel bearings from affecting the
measurement.
4 Measure the vertical play at the outer tip of
the stub axle while moving the wheel
101 170
sideways. Use a dial indicator.

Movement of king pin bearing
Note: Move the wheel smoothly so that the A max = 1.0 mm
position of entire front vehicle unit is not Indicator stand 587571
disturbed.

Front axles
Ball joint
1 Lower the front wheels into straight-ahead
position.
2 Place an indicator dial in line with the ball
joint pin.
3 Clamp the ball joint with adjustable pliers
and read off the play.
4 Repeat the measurement on the other ball
joints.
Note: If the play is greater than 2.0 mm, the ball
113 254
joint must be replaced.
Play in ball joint: max. 2.0 mm

Front axles
7-04 Measuring toe-in

Gauge rod (part no. 587 690)
1 Drive the vehicle forward and come to a
standstill on a level surface with the front
wheels pointing straight ahead.
2 Measure distance a. See illustration.
3 Mark the points of measurement on the
rims.
4 Move the vehicle forward so that the
measuring points are in position to measure
b, i.e. half a revolution forward.
5 Measure distance b. See illustration.
Note: This method is not as accurate as

measuring with laser.
The following setting values apply at

maximum axle weight
07_0271
Steering axle Toe-in measured
with gauge rod
All 0 to +1.5 mm
Measuring with laser is always recommended

on vehicles with crane mounted behind the cab
and on vehicles with heavy bodywork at the
rear. Refer to group 13 in the Workshop Manual.
113 255

Rear axles
8 Rear axles
8-01 Changing oil in axle
gear
In extremely demanding conditions, we
recommend SAE 75W-140 synthetic oil.
! WARNING!

gloves and goggles.
1 Place a collecting vessel under the axle

gear.
1 2
2 Drain the oil when it is hot.
3 Clean the magnet on the drain plugs and
level plugs.
4 If there is a filter on the axle: Remove the
filter.
Note: Check that the old gasket is attached

when the filter is removed.
100 873
3
5 Lubricate the rubber gasket for the new
filter with oil. 1 Oil filter with protection cover
6 Screw on the filter by hand until the gasket 2 Level plug
rests against the housing. Tighten the filter 3 Drain plug
a further half turn. Refit the protection
cover.
7 Refit the drain plug and fill with oil
through the level hole. Tighten to 100 Nm.
8 Refit the level plug and torque tighten to
100 Nm.

Rear axles
The oil circulates between hub reduction gears

type RH 735, RH 835 and central gears type
RP/RBP 735, 835. The oil in both the hub
reduction gears and the central gears must
therefore be drained before new oil is filled.
128 243
Oil capacities Oil filter position on axle gears type
RBP 735, 835
Oil capacities Litres
RP 730 10.0
R 560, 660, 780 (Filter) 12.5
RBP 730, RB 660 (Filter) 14.0
RP 832 14.0
RBP 832 14.0
RP 735 (Filter) 8.0

RP 835 (Filter) 9.3
RBP 735 (Filter) 11.2
RBP 835 (Filter) 12.0
Note: The values are approximate. Check the oil

level. Top up if necessary. Oil level down to
10 mm below the level hole is acceptable.

Rear axles
8-02 Tag axle lift
Oil level
When the tag axle is lowered, the oil level
should be between the dipstick marks.
100912
8-03 Tag axle 6x2, 8x2
Check-tightening the balance arm bearing nut.
1 Remove the protection cover with the

gasket for balance arm bearing.
2 Bend up the lock plate.
3 Tighten the nut to 425 Nm, see illustration.
4 Bend the lock plate against one of the nut
flats and fit the protection cover.

Hubs and wheels
9 Hubs and Wheels

9-01 Hub reduction gears
Oil change RH 730,731,832

Oil grade: Oils, refer to booklet 00:03-09. 2
1
reduction gear.
2 Clean the hub cover.
3 Rotate the hub until the drain plug 3 points
straight down. Refer to illustration
Draining.
100910
3
Draining
4 Remove the drain plugs and filler plugs 2 1 Marking line
and 3. Drain the oil.
2 Filler plug
5 Turn the hub until the cover marking line 1 3 Drain plug
is in a horizontal position. Refer to
illustration Filling.
6 Add oil through the upper hole 2 until oil
runs out of the lower hole 3.
1
7 Replace the filler and drain plugs and 2
tighten to 10 Nm.
Oil capacity Litres

RH 730, 832 2.0
RH 731 0.8
3
08 1564
Filling

Hubs and wheels
Oil change RH 735, 835

The oil circulates between the hub reduction
gears RH735/835 and the central gear
RBP/RP735/835. The oil level in the hub
reduction gears may therefore vary depending
on how the vehicle has been driven before it was
brought into the workshop. Refer to function
description for hub reduction gears in the
Workshop Manual, main group 9.
! WARNING!
Use protective goggles when draining oil

from the hub reduction gear. Oil can
spray out at high pressure.
Help protect our environment. Dispose of excess

oil in accordance with workshop procedures.
Draining oil
Note: The oil in both the central gear and the

hub reduction gear must be drained before new
oil can be filled.

reduction gear.
2 Turn the hub reduction gear so that the oil
plug 1 is at the lowest level.
3 Drain the oil.

127 269

Hubs and wheels
Filling with oil

2
1 Turn the hub reduction gear so that the oil
level mark 2 on the hub cover is in a
horizontal position.
2 Fill up with oil.
3 Refit the oil plug 1. Tightening torque

40 Nm.
IMPORTANT! Check the oil level in both hub

reduction gears and in the central gear after
filling. Refer to the section on Checking oil
level.
127 270
1
Oil capacity Litres

RH 735, 835 2.0
Checking oil level

1 Place collecting vessels under both hub
reduction gears and the central gear.
2 Check the oil level in both hub reduction
gears and the central gear.
3 Top up with oil if the oil level is too low.
Drain oil if the oil level is too high.

Hubs and wheels
9-02 Checking front wheel

bearings
1 Support the front vehicle unit by placing
supports under the front axle and release the
parking brake.
2 Rotate the wheels with a wheel spinner.
105 805
Listen for any noise from the bearings.
3 Check for grease leaks.
4 Unscrew the plug from the centre hole of

the hub cap and screw in a 50 mm long fully
threaded M20 bolt. Tighten the screw until
the cover comes off.
5 Position dial gauge 98 075 and magnetic
foot 587 250 as illustrated. The measuring
tip should be placed along the centre line of
the shaft journal.
6 Press and turn the hub by hand
105 806
simultaneously until the wheel bearings fit.
Zero the dial gauge.
7 Pull out and turn the hub simultaneously.
Read the bearing play. Take the
measurement several times and work out an
average value.
8 If the play is greater than 0.2 mm, the

bearing must be renewed. 105 807
Maximum axial clearance

Front axle 0.2 mm

Hubs and wheels
9-03 Check tightening

wheel nuts
1 When tightening wheels with disc rims, use
a torque socket or an impact nut runner
which provides 1500-2700 Nm with torque
socket 98 661.
2 7
6
2 Tighten aluminium plate rims and spoke 9
4
wheels with a torque wrench. 10
3
5
3 Tighten the nuts in the order shown in the 8 1
illustrations.
09_0464
4 For vehicles with spoke wheels:
Check-tighten the nuts for the brake drum.
Disc wheel
Special tools
Torque socket, disc wheel 98 661
Socket, spoke wheel 588 117
113 256
Tightening torques
Spoke wheel, old model
Disc wheel 600 Nm
Spoke wheel 28 inches 315 Nm
Other spoke wheels 350 Nm
Brake drum secured in spoke 270 Nm
wheel hub

Hubs and wheels
9-04 Checking the tyres

1 Check that tyre wear is even and evenly
distributed across the whole tread.
2 Check tread depth: The tread depth must not
be below 3 mm if the tyres are to be
retreaded. Regarding traffic safety the
minimum tread depth is 3.0 mm. The worn-
tyre warning is for 1.6 mm.
3 Check the tyre pressure. Refer to Operator's
Manual OM-25 Wheel change instructions
and tyre manufacturer's instructions.
Observe also applicable legislation and
regulations.
Note: Pay attention to legislation regarding

tread depth. It may vary between countries.

WSM - Maintenance Instruction Part - 1 Truk - en PDF

Uploaded by

Copyright:

Available Formats

WSM - Maintenance Instruction Part - 1 Truk - en PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WSM - Maintenance Instruction Part - 1 Truk - en PDF

Uploaded by

Copyright:

Available Formats

What are the main components discussed in the maintenance instructions?

What are the main components discussed in the maintenance instructions?

What lubrication procedures are described?

What lubrication procedures are described?

00:03-07/1

Maintenance instructions part 1

© Scania CV AB 2005, Sweden

0 General Inspection form ............................................... 5

1 Engine 1-01 Oil change ..................................................... 27

2 Cooling system 2-01 Coolant .......................................................... 61

3 Fuel and exhaust systems 3-01 Renewal of fuel filter, bleeding..................... 70

4 Clutch 4-01 Fluid level in clutch control .......................... 85

5 Gearbox 5-01 Manual gearbox............................................. 91

6 Propeller shafts 6-01 Checking propeller shafts, support

2 © Scania CV AB 2005, Sweden 00:03-07/1

7 Front axles 7-01 Changing oil in axle gear ............................ 105

8 Rear axles 8-01 Changing oil in axle gear ............................ 110

9 Hubs and Wheels 9-01 Hub reduction gears .................................... 113

00:03-07/1 © Scania CV AB 2005, Sweden 3

Changes from the previous issue

4 © Scania CV AB 2005, Sweden 00:03-07/1

• Maintenance Programme - Preface

Make copies of the reports as required.

printed using the PC software Scania Main.

00:03-07/1 © Scania CV AB 2005, Sweden 5

Vehicles with air suspension

For more information on safety measures, see

6 © Scania CV AB 2005, Sweden 00:03-07/1

0-01 Chassis lubrication

Lubricating with grease gun

Note: When lubricating with grease, make sure

8 © Scania CV AB 2005, Sweden 00:03-07/1

00:03-07/1 © Scania CV AB 2005, Sweden 9

Lubrication points 4x4 Z, 6x6 Z

10 © Scania CV AB 2005, Sweden 00:03-07/1

Lubrication points 4x2 A/B

00:03-07/1 © Scania CV AB 2005, Sweden 11

Lubrication points 4x2 Z, 4x4 Z

12 © Scania CV AB 2005, Sweden 00:03-07/1

Lubrication points 6x2 A/B, 8x2 A/B

2 Brake slack adjuster

00:03-07/1 © Scania CV AB 2005, Sweden 13

Lubrication points 6x2 Z, 8x2 Z

14 © Scania CV AB 2005, Sweden 00:03-07/1

Lubrication points 6x4 Z, 6x6 Z, 8x4 Z, 8x8 Z

2 Brake slack adjuster

00:03-07/1 © Scania CV AB 2005, Sweden 15

Lubrication points 6x4 A/B, 8x4 A/B

2 Brake slack adjuster

16 © Scania CV AB 2005, Sweden 00:03-07/1

Lubrication points 6x2/4 A/B, 8x2/4 A/B

2 Brake slack adjuster

00:03-07/1 © Scania CV AB 2005, Sweden 17

Lubrication points 6x2*4 A/B, 8x2*6 A/B

2 Brake slack adjuster

18 © Scania CV AB 2005, Sweden 00:03-07/1

Lubrication points 8x4*4 A/B

2 Brake slack adjuster

00:03-07/1 © Scania CV AB 2005, Sweden 19

Lubrication points 6x24 A/B, 8x26 A/B