Volvo FL12 Truck Service and Repair Manual

Volvo FL12 Truck Service and Repair Manual

Size: 293.50 MB
Format: PDF
Language: English
Machine: Truck
Document: Service and Repair Manual, Hydraulic and Electrical Diagrams
Machine Model: FL12 
Pages: 3062 Pages

The Bookmarks of Volvo FL12 Truck Service and Repair Manual:
All Service Information-Index
Bulletins - Information
 9992876 Spacer sleeve
 Altering connector, oil pressure sensor
 Altering connector, oil pressure sensor1
 Modification of cable harness for new brake contacts or horn
 New Accelerator Pedal Sensor (Australia)
 Volvo RoadRelay and Volvo InRoads Office
Bulletins - Information-Index
Description, Design and Function
 64331-3 Steering arm, replace (one)
 Air drier
 Air suspension, system description
 Anti-lock brake system (ABS)1
 Anti-lock brake system (ABS)2
 Anti-roll bar, rear
 Automatic transmission
 Basic gearbox
 Basic housing
 Bogie lift1
 Bogie lift2
 Bogie lift3
 Cables clamping
 Clutch linkage
 Compressor1
 Compressor2
 Compressor3
 Control housing
 Control system components
 Cooling system
 Diaphragm spring
 Diesel fuel
 Differential carrier, section view
 Differential carrier
 Disc
 Double disc clutch
 Electrical system
 Electronic control unit sensors
 Electronic control unit
 Electronic unit injector operational phases
 Electronic unit injectors
 Exhaust pressure governor
 Final drive (front and rear) R3 - Group 465
 Front air suspension, components1
 Front air suspension, components2
 Front hub, components
 Fuel feed pump
 Fuel filter
 Fuel flow
 Fuel system1
 Gear selector controls FL7, FL10, FL12
 Gearbox construction
 Gearbox, automatic, drawing
 General quality requirements R3 - Group 0
 General R3 - Group 593
 General
 General1
 General2
 Hand primer
 Hub reduction, exploded view
 Hub reduction, section view
 Lubrication system
 Marking engines
 Non-return valve
 Oil cooler cover
 Operating system, components
 Overflow valve
 Pneumatic system
 Position diagram, ABS FL7, FL10
 Power path1
 Power path2
 Power take-off
 Power take-off1
 Power take-off2
 Pressure limiting valve (pos 51)
 Pressure limiting valve
 Product information on Volvos for emergency services personnel
 Programme description (ToolBox)
 Propeller shaft
 R3 - Group 230 233 234 236 237 238
 R3 - Group 437
 Range gear
 Rear axle, general
 Release bearing
 Road Relay R3 - Group 082 200
 Road Relay, configuration and installation
 Road Relay, downloading data
 Road Relay, operation
 Road Relay, Starting and Exiting
 Safety valve
 Single disc clutch
 Spring cradle and stay
 Starter motor
 Steering knuckle, exploded view
 Straps
 Symbol index
 The ESS function
 Torque converter pressure PC
 Towing information
 Trailer brake circuit FL
 Transfer gear,1
 Transfer gear,2
 Tyre and inner tube
 VSP program
 VSP
 V-stay, reaction rod rear end
 Wheel brake
Description, Design and Function-Index
Diagnostics
 23705-3 Electrical system, unit injector, check
 26311-2 Thermostat controlled fan, function check
 28450-3 MID 128 PID 45 Preheater relay, check
 56123-3 Compressor, function and leakage check
 56133-2 Air drier, function check
 Abnormal smoke, fault tracing
 Actions brake vibrations
 Basic check1
 Basic check2
 Battery analyser 7200 user manual
 Battery analyser, 7200, user manual
 Battery analyzer, 88890075 EXP, user manual
 Battery analyzer, 88890075 EXP, user manual1
 Boost pressure, fault tracing
 Brake vibrations, fault tracing
 Cables and connectors, fault tracing
 Connectors, control system (sump)
 Coolant temperature, fault tracing
 Display
 Dual draw dual return fuel system troubleshooting
 Electrical Fault Tracing
 Engine1
 Engine2
 Fault code fault tracing
 Fault code table
 Fault tracing, general information1
 Fault tracing, general information2
 Fault tracing
 Fuel feed pressure, fault tracing
 Fuel system and used lubricant oil analysis, fault tracing
 Gearbox fault codes reading, check connection with VOLVO diagnostic tool
 General EV87
 Inductive sensor
 Malfunction (ToolBox)
 Malfunctions, causes and remedial actions
 Malfunctions, causes and remedial actions1
 Mechanical fault tracing
 MID 128 Engine control unit, fault codes
 Powertronic diagnosis and fault tracing R3 - Group 437
 Ready-reference, fault codes
 Report for monitoring oil and fuel consumption
 R-SR-SRO1000-2400
 Start and stop problems, fault tracing
 Status tests
 Test instrument for checking speed limiter, range inhibitor
 Timer relay 3017
 VSP
Diagnostics-Index
Forms
 Annual service
 Annual service1
 Annual service2
 Basic service
 Battery, warranty claim handling, additional information
 Manual gearbox, warranty claim handling, additional information
 Oil and fuel consumption, follow-up
Forms-Index
Repair
 21002-2 Cylinder compression test
 21035-4 Engine parts, transferring
 21070-1 Engine, remove
 21072-1 Engine, install
 21122-1 Cylinder head, remove
 21124-1 Cylinder head, install
 21171-4 Cylinder head, pressure test (first)
 21233-3 Flywheel housing, replace
 21235-3 Flywheel housing run-out, check
 21307-3 Cylinder liner seat, milling (first)
 21311-3 Cylinder liners and pistons, replace (All)
 21405-5 Valves, remove and install (one cylinder)
 21414-3 Valves and engine injectors, adjust
 21415-5 Valve guides, replace (one cylinder head)
 21416-2 Valve stem seals, replace
 21491-4 Valves grind and decarb (first cylinder head)
 21511-3 Timing gear plate, adjust
 21513-3 Camshaft wear, check
 21522-2 Camshaft, replace
 21524-3 Camshaft bearing brackets, replace. Camshaft removed
 21534-2 Seal, drive mechanism, fan, alternator and AC, replace
 21538-4 Drive mechanism, fan, alternator and AC, overhaul
 21603-3 Main bearings, replace (all)
 21607-3 Flywheel bearing, replace
 21611-3 Connecting rod bearings, replace (all)
 21632-2 Flywheel sensor distance, check
 21667-3 Crankshaft seal, replace (rear)
 21687-5 Flywheel ring gear, replace
 22111-3 Oil pump, remove-install
 22121-2 Oil pressure, check
 22207-3 Oil filter, engine, replace
 22210-2 Oil filter, replace
 22322-3 Oil cooler insert, replace
 22325-5 Oil cooler, pressure test
 22330-2 Overflow valve, oil filter, replace
 22335-2 Overflow valve, oil cooler, replace
 22337-2 Piston cooling valve, replace
 22341-2 Reduction valve, replace
 23003-3 Fuel system, bleeding
 23005-2 Smoke gas test in vehicle
 23302-2 Feed pump, replace
 23303-2 Fuel filter, replace (one)
 23307-3 Hand pump, feed pump, replace
 23308-2 Hand pump, overhaul
 23312-2 Filter, water separator, replace
 23314-2 Water separator, water draining1
 23314-2 Water separator, water draining2
 23326-2 Feed pump valves, replace
 23378-2 Fuel feed pressure, check
 23397-4 Fuel feed pump, overhaul
 23415-3 Fuel tank strainer, clean and drain condensation water
 23607-3 Overflow valve, replace
 23724-2 Delivery pipes, replace (all)
 23733-3 Sleeve, unit injector, replace
 23734-2 Unit injector, replace (one)
 23742-3 Ball socket unit injector, replace
 23821-2 Engine control unit, replace
 25102-2 Gaskets, intake manifold, replace1
 25102-2 Gaskets, intake manifold, replace2
 25316-2 Exhaust pressure governor, replace
 25318-4 Exhaust pressure governor, overhaul
 25514-2 Turbo boost gauge, remove-install
 25518-2 Engine turbocharger, replace1
 25518-2 Engine turbocharger, replace2
 25624-2 Filter insert, air cleaner, replace
 26007-3 Cooling system, clean
 26106-2 Radiator, external cleaning
 26108-2 Radiator, replace1
 26108-2 Radiator, replace2
 26123-3 Coolant filter, replace
 26202-2 Coolant pump, replace
 26214-2 Piston thermostat, replace
 26271-4 Coolant pump, overhaul
 26273-4 Thermostats, test
 26304-2 Drive belt, replace
 26310-2 Fan belt tensioner, overhaul
 26313-2 Fan belt tensioner, replace
 26315-4 Spring, fan belt tensioner, replace
 26323-2 Fan hub, replace
 26504-2 Charge air cooler, leakage test
 27106-2 Sensor, accelerator pedal, replace
 35126-2 Control lamp, replace
 36440-2 Break contact clutch pedal, replace
 37130-2 Trailer connection, replace
 41103-3 Clutch plate, replace
 41277-5 Clutch fork and clutch shaft, replace
 41283-5 Release bearing, pulling clutch replace1
 41283-5 Release bearing, pulling clutch replace2
 41314-2 Clutch cylinder, replace
 41316-2 Clutch servo, adjust
 41342-2 Clutch system, bleed
 41375-4 Clutch servo, overhaul1
 41375-4 Clutch servo, overhaul2
 43003-2 Gear shift mechanism, adjust
 43125-4 Split cylinder, overhaul
 43130-2 Output shaft sealing ring, replace
 43141-5 Oil pump, overhaul
 43156-2 Splitter gear, check and adjust
 43160-2 Master cylinder gear selector, overhaul
 43163-2 Control cylinder, overhaul
 43170-1 Gearbox, remove
 43172-1 Gearbox, install
 43173-5 Main shaft, overhaul1
 43173-5 Main shaft, overhaul2
 43174-1 Range gear, remove
 43175-5 Range gear, overhaul1
 43175-5 Range gear, overhaul2
 43176-1 Range gear, install
 43181-5 Countershaft, overhaul
 43187-4 Gearbox, disassemble-inspect-assemble1
 43187-4 Gearbox, disassemble-inspect-assemble2
 43195-5 Reverse shaft, overhaul
 43197-5 Input shaft, overhaul1
 43197-5 Input shaft, overhaul2
 43206-2 Gear lever, replace
 43223-2 Springs, gear lever fork, replace
 43248-2 Gear lever knob, overhaul
 43258-2 Control cylinder front, replace
 43260-2 Control cylinder rear, replace
 43264-2 Master cylinder gear shift, replace
 43266-2 Range cylinder, overhaul
 43273-4 Control cylinder for high and low gear ranges, overhaul1
 43273-4 Control cylinder for high and low gear ranges, overhaul2
 43278-4 Control housing, overhaul
 43701-3 Control valve bodies, clean
 43721-4 Gearbox, disassemble
 43724-4 Gearbox, assemble
 43744-4 Clutch housing 1, overhaul1
 43744-4 Clutch housing 1, overhaul2
 43746-4 Oil pump, overhaul
 43748-4 Stator shaft, overhaul
 43750-4 Ring gear planetary kit 3, replace
 43760-4 Clutch housing 2, overhaul1
 43760-4 Clutch housing 2, overhaul2
 43762-5 Piston, overhaul (one)
 43768-4 Bushing sun gear, replace
 43770-4 Planetary gear carrier 1-2-3-4-5, check
 43778-5 Planetary gear carrier 1 or 2, overhaul1
 43778-5 Planetary gear carrier 1 or 2, overhaul2
 43780-4 Bushing planetary gear carrier, replace
 43782-4 Bushing planetary gear carrier 2, replace
 43784-5 Retarder valve, check and seal, replace
 43785-5 Rear cover, overhaul
 43786-5 Bearing intermediate gear PTO, replace
 43788-5 Planetary gear carrier 4, overhaul. Removed
 43790-5 Planetary gear carrier 3, overhaul
 43792-5 Planetary gear carrier 5, overhaul. Removed
 43793-5 Output shaft, overhaul
 43794-5 Bushing planetary gear carrier 5, replace
 45122-2 Universal joint angles, check and calculate
 45171-4 Universal joints, replace (each)
 45312-2 Support bearing, overhaul
 46514-2 Pinion sealing ring, replace
 46570-1 Differential carrier, remove
 46571-4 Differential carrier, overhaul1
 46571-4 Differential carrier, overhaul2
 46571-4 Differential carrier, overhaul3
 46571-4 Differential carrier, overhaul4
 46572-1 Differential carrier, install
 46656-2 Hub reduction, overhaul (one side)1
 46656-2 Hub reduction, overhaul (one side)2
 46802-2 Diff lock, check and adjust disengage and engage position
 46803-3 Diaphragm sleeve, adjust
 46805-2 Switch, differential lock, check and adjust
 48170-1 Power take-off, remove1
 48170-1 Power take-off, remove2
 48171-4 Power take-off, overhaul1
 48171-4 Power take-off, overhaul2
 48172-1 Power take-off, install1
 48172-1 Power take-off, install2
 48203-4 Koblam upper housing, overhaul
 51085-4 Brake cylinder, overhaul (single diaphragm)
 56111-2 Compressor, replace1
 56111-2 Compressor, replace2
 56112-2 Pressure governor, adjust
 56116-2 Air drier, replace
 56117-4 Air drier, overhaul1
 56117-4 Air drier, overhaul2
 56125-3 Air drier insert, replace
 56126-2 Air drier, drier insert, replace1
 56126-2 Air drier, drier insert, replace2
 56128-2 Compressor loading time, check
 56131-5 Piston, connecting rod, replace
 56134-2 Air-drier preheating element, replace
 56135-2 Solenoid valve, air drier, replace
 56136-2 Air drier non return valve, replace
 56142-2 Pressure regulator, replace
 56152-4 Compressor piston rings, replace1
 56152-4 Compressor piston rings, replace2
 56152-4 Compressor piston rings, replace3
 56153-5 Compressor, check and wear measurement
 56171-4 Compressor, overhaul1
 56171-4 Compressor, overhaul2
 56171-4 Compressor, overhaul3
 56173-4 Pressure governor, overhaul1
 56173-4 Pressure governor, overhaul2
 56183-2 Air drier, valve unit replace
 56306-2 Trailer brake control valve, overhaul
 56316-2 Relay valve, overhaul
 56320-4 Pressure limiter valve, overhaul
 56336-2 Control valve, overhaul
 56338-2 Pressure limiter valve, replace
 56357-2 Quick release valve (front), overhaul
 56370-2 Overflow valve, no return flow, replace
 56372-4 Bogie lift valve, overhaul
 56373-4 Footbrake valve, overhaul
 56377-2 Overflow valve with return flow, replace
 56381-4 Overflow valve with return flow, overhaul
 56384-4 Overflow valve, no return flow, overhaul
 56392-5 Pressure limiting valve, adjust
 57106-4 Trailer brake control, overhaul
 61103-3 Steering knuckle, overhaul (one)1
 61103-3 Steering knuckle, overhaul (one)2
 64282-1 Steering gear, remove
 64284-1 Steering gear, install
 65212-2 Bushings, reaction rod, replace (one side)
 65246-2 Bushings, front reaction rod, replace (one side)
 65270-1 V-rod, remove
 65271-5 V-rod, outer ball joint, overhaul
 65272-1 V-stay rod, install
 65273-5 V-rod, centre joint, overhaul
 65516-4 Spring cradle, overhaul1
 65516-4 Spring cradle, overhaul2
 65525-3 Shaft, spring cradle, replace1
 65525-3 Shaft, spring cradle, replace2
 65570-1 Spring cradle, remove1
 65570-1 Spring cradle, remove2
 65570-1 Spring cradle, remove3
 65572-1 Spring cradle, install1
 65572-1 Spring cradle, install2
 72508-2 Front anchorage, reaction rod, replace
 72514-2 Level valve, front axle, setting1
 72514-2 Level valve, front axle, setting2
 72514-2 Level valve, front axle, setting3
 72515-2 Level valve, non-return valve and control valve, replace
 72516-2 Level valve front axle, replace
 72602-2 Air bellows, drive axle, replace
 72604-2 Levelling valve drive axle, replace (one)
 72612-2 Highest control position rear, adjust
 72613-3 Brake contact, max control position, replace
 72616-2 Bellow plate, rear, replace
 72625-4 Level valve, basic setting
 72627-4 Level valve, overhaul
 72636-2 Level valve, non-return valve and control valve, replace
 72815-2 Solenoid valve, bogie lift, replace
 72840-4 Solenoid Valve, Air Suspension, Overhaul
 72844-2 Solenoid coil, air suspension, replace
 76204-2 Rubber journal and bushing, anti roll bar front, replace
 76435-4 Solenoid valve, overhaul
 76436-2 Levelling valves, rear axle, setting1
 76436-2 Levelling valves, rear axle, setting2
 76436-2 Levelling valves, rear axle, setting3
 77101-2 Spoke wheel, replace
 77102-2 Disc wheel, replace
 77103-3 Disc wheel, check
 77145-3 Wheel nuts, check tightening (all)
 77333-4 Front wheel bearing, wear ring and sealing ring, replace
 77334-2 Rear wheel bearing, adjust (one wheel)
 77363-2 Rear wheel bearing and seal, replace1
 77363-2 Rear wheel bearing and seal, replace2
 77365-3 Front wheel hub, remove
 77371-3 Front wheel hub, install
 81804-2 Tilt cylinder, re-gasket
 81814-2 Cab tilt pump, re-gasket
 81828-2 Cab tilt pump, pressure checking
 81870-1 Cab, remove
 81872-1 Cab, install
 81876-2 Cab bracket, replace (two sides)
 82310-2 Radiator grille, replace
 83131-2 Door stop, replace
 83138-2 Door hinges, adjust (one door)
 83145-2 Door guide, adjust (one)
 83402-2 Door handle inside, replace
 83404-2 Door handle outside, replace
 83408-2 Lock cylinder, replace (one)
 83414-2 Door lock, replace (one side)
 83505-2 Window lift, replace
 83610-2 Roof hatch, replace
 84302-2 Windscreen, replace
 84406-2 Door window, replace
 84602-2 Heater plate rear view mirror, replace
 85150-1 Door upholstery, remove
 85151-1 Door upholstery, install
 85505-1 Headlining, install
 85507-1 Headlining, remove
 87520-3 Flame indicator, replace
 87521-3 Seals, heat exchanger, replace
 87522-3 Seals, fan, replace
 87525-3 Ignition electrodes, replace
 87526-3 Glow plug strainer, replace
 87527-3 Circuit board, replace
 87528-3 Discharge cap, replace
 87530-3 Casing cover, replace
 87531-3 Overheating breaker, replace
 87578-2 Carbon dioxide content, check and adjust
 Adjusting the differential lock indication
 Automatic transmission, modification
 Balancing the propeller shaft
 Cable repair
 CD-ROM Reader to disc drive, changing
 Check, wear in cam housing
 Clutch plate, marking
 Clutch, check and replacement of components
 Cooling system, leak test
 Electrically operated rearview mirror, changing motor
 Exhaust temperature, check
 Fuel system, draining
 Installation of oil filter and strainer
 Level control, adjustment
 Level valve front, changing
 Pressure switch located at the pedal carrier, FL10 and FL12
 Procedures when turning the engine over with the starter motor
 Procedures when working on a truck fitted with electronic fuel injection
 Range cylinder, adjust
 Replacing output shaft bearing1
 Replacing output shaft bearing2
 Replacing the silencer
 Retroactive fitting of the corrugated plastic hose
 Tachograph speedometer, calibration
 Valve block, clutch control, changing
 Valve guides, inspection
 Working with chemicals
Repair-Index
Schematic Diagrams
 Diagram 1. FL12 4x2
 Diagram 6. FL12 6x2
 Diagram 12. FL12 6x4
 Diagram 14. FL12 8x2
 Diagram 15. FL12 8x4
 Electric schematic
 Hydraulic schematic
Schematic Diagrams-Index
Service and Maintenance
 17504-2 Lubrication according to actual lubrication chart
 17523-3 Gearbox oil and filter, replace
 17527-3 Final drive oil, change
 17528-3 Retarder, oil change
 17530-3 Transfer gearbox, oil change
 17561-3 Final drive with hub reduction, oil change
 17577-3 Power take-off, oil and filter, change
 17582-3 Driven front axle, oil change
 17706-2 Cab heater, maintenance service
 17725-3 Driver's service, optional1
 17725-3 Driver's service, optional2
 17746-2 Annual service
 43137-3 Oil pressure, check
 Additional procedures, basic and annual service
 Air drier, check
 Annual service, general
 Check of high pressure monitor
 Cleanliness in the clutch system
 Hydraulic pump, service
 Lubrication chart
 Oil filter protection
 Parking heater
 Preventive maintenance intervals
 Washing, polishing and waxing, cab
Service and Maintenance-Index
Specifications
 64028-2 Power steering, function check
 64313-2 Ball joint, link rod and track rod, axial play, check
 72820-1 Levelling control manual, electrical system, function check1
 72820-1 Levelling control manual, electrical system, function check2
 Accelerator pedal sensor
 Air suspension, electrical components
 Air suspension, mechanical components
 Air suspension, pneumatic components
 Alignment measurements R3 - Group 650
 Axial play1
 Axial play2
 Brake components
 Cab R3 - Group 818
 Cab suspension troubleshooting R3 - Group 818
 Checking the bogie lift and bogie press functions
 Compressed-air tank
 Compressed-air tank1
 Compressor
 Cooling system
 Diagram decal for load sensing valve
 Engine control system
 Final drive1
 Final drive2
 Final drive3
 Final drive4
 Front axle
 Fuel system
 Gearbox, automatic1
 Gearbox, automatic2
 Gearbox, automatic3
 Gearbox, automatic4
 Gearbox, automatic5
 Gearbox, automatic6
 Gearbox, automatic7
 Gearbox, automatic8
 Gearbox, automatic9
 General instructions
 General1
 General2
 General3
 Hub
 Hubs, tightening torques
 Hydraulic system, fault tracing
 Intake and exhaust system
 Level control
 Lubricating and oil system
 Oil pump
 Pedal play
 Power take-off
 Press forces1
 Press forces2
 Propeller shaft
 Pulling clutch, double disc
 Pulling clutch, single disc
 Rear axle1
 Rear axle2
 Rear axle3
 Safety valve (pos. 1a, 21, 21a)
 Seats R3 - Group 852
 Short stroke synchronization
 Specifications
 Specifications1
 Speed sensor with O-ring
 Syncronizer1
 Syncronizer2
 The pressure monitor's cut-off values
 Tightening torques and patterns
 Tightening torques1
 Tightening torques2
 Tightening torques3
 Tightening torques4
 Tightening torques5
 Tightening torques6
 Tightening torques7
 Tightening torques8
 Tightening torques9
 Tightening torques10
 Trailing axle
 Transfer box
 Tyre and inner tube
 Valves
 VCADS, VSP and Brake Adaptation, CD
 Water pump
 Wheel alignment
 Wheel installation
 Wheel
Specifications-Index