Volvo FL4 Truck Service and Repair Manual

Volvo FL4 Truck Service and Repair Manual

Size: 70.28 MB
Format: PDF
Language: English
Machine: Truck
Document: Service and Repair Manual
Machine Model: FL4 
Pages: 1550 Pages

The Bookmarks of Volvo FL4 Truck Service and Repair Manual:
21235-3 2125-06-03-02 Flywheel housing run-out, check
23724-2 2373-03-02-02 Delivery pipes, replace (all)
26106-2 2611-11-02-01 Radiator, external cleaning
26273-4 2627-06-04-01 Thermostats, test
27510-3 2759-03-02-01 Cable, electrical motor, replace
31102-2 3111-03-02-01 Batteries, replace (all)
35126-2 3514-03-02-06 Control lamp, replace
41103-3 4117-03-03-01 Clutch plate, replace  1
41103-3 4117-03-03-01 Clutch plate, replace 2
41185-2 4111-05-02-01 Clutch, adjust
41314-2 4134-03-02-03 Clutch cylinder, replace
43130-2 4339-03-02-01 Output shaft sealing ring, replace 1
43130-2 4339-03-02-01 Output shaft sealing ring, replace 2
43137-3 4319-06-03-01 Oil pressure, check
43165-5 4311-13-05-01 Gearbox, disassemble-inspect-prepair for transport
43167-5 4311-14-05-02 Gearbox, assemble
43170-1 4311-01-01-01 Gearbox, remove
43172-1 4311-02-01-01 Gearbox, install
43173-5 4313-04-05-01 Main shaft, overhaul
43175-5 4319-04-05-02 Range gear, overhaul
43181-5 4313-04-05-02 Countershaft, overhaul
43197-5 4313-04-05-04 Input shaft, overhaul
43266-2 4319-04-02-01 Range cylinder, overhaul
43278-4 4329-04-04-05 Control housing, overhaul
43728-2 4371-06-02-01 Automatic transmission main pressure, measure
45122-2 4511-06-02-01 Universal joint angles, check and calculate 1
45122-2 4511-06-02-01 Universal joint angles, check and calculate 2
45122-2 4511-06-02-01 Universal joint angles, check and calculate 3
45122-2 4511-06-02-01 Universal joint angles, check and calculate 4
45122-2 4511-06-02-01 Universal joint angles, check and calculate 5
45122-2 4511-06-02-01 Universal joint angles, check and calculate 6
46514-2 4658-03-02-01 Pinion sealing ring, replace 1
46514-2 4658-03-02-01 Pinion sealing ring, replace 2
46534-5 4659-04-05-01 Shift unit, differential lock, overhaul 1
46534-5 4659-04-05-01 Shift unit, differential lock, overhaul
46570-1 4651-01-01-01 Differential carrier, remove 1
46570-1 4651-01-01-01 Differential carrier, remove 2
46571-4 4651-04-04-01 Differential carrier, overhaul 1
46571-4 4651-04-04-01 Differential carrier, overhaul 2
46572-1 4651-02-01-01 Differential carrier, install 1
46572-1 4651-02-01-01 Differential carrier, install 2
46802-2 4681-06-02-01 Diff lock, check and adjust disengage and engage position
46803-3 4689-05-03-01 Diaphragm sleeve, adjust
48170-1 4811-01-01-01 Power take-off, remove
48171-4 4811-04-04-01 Power take-off, overhaul 1
48171-4 4811-04-04-01 Power take-off, overhaul 2
48172-1 4811-02-01-01 Power take-off, install
51121-3 5115-03-03-01 Brake pads, replace (two front wheels)
51131-3 5117-04-03-01 Brake caliper, overhaul (one front wheel)
51137-3 5117-03-03-02 Brake caliper front wheel, replace
51145-3 5112-03-03-01 Brake disc, front wheel, replace
51221-3 5125-03-03-01 Brake pads, replace (two rear wheels)
51235-3 5127-04-03-01 Brake caliper, overhaul (one rear wheel)
51237-3 5127-03-03-01 Brake caliper rear wheel, replace
56373-4 5631-04-04-01 Footbrake valve, overhaul
57106-4 5711-04-04-01 Trailer brake control, overhaul
60110-2 6010-06-02-01 Wheel angles, check-measure (all) 1
60110-2 6010-06-02-01 Wheel angles, check-measure (all) 2
60110-2 6010-06-02-01 Wheel angles, check-measure (all) 3
60124-2 6010-06-02-02 Toe-in, check
60131-3 6010-05-03-01 Toe-in, adjust
61002-2 6010-06-02-03 Front end wear, check
61103-3 6113-04-03-01 Steering knuckle, overhaul (one) 1
61103-3 6113-04-03-01 Steering knuckle, overhaul (one) 2
61270-1 6121-01-01-01 Front axle complete, remove
61272-1 6121-02-01-01 Front axle complete, install
64028-2 6459-08-02-01 Power steering, function check
64104-2 6411-03-02-01 Steering wheel, replace
64106-2 6412-03-02-01 Steering shaft bearings upper and lower, replace
64210-2 6429-03-02-03 Sealing ring, steering spindle, replace
64252-2 6429-06-02-01 Pressure point, steering gear, check and adjust
64282-1 6422-01-01-01 Steering gear, remove
64284-1 6422-02-01-01 Steering gear, install
64312-2 6438-03-02-01 Link rod, replace
64357-5 6432-03-05-01 Track rod end, replace (one)
64370-1  Track rod, remove
64372-1 6431-02-01-01 Track rod, install
64514-2 6459-03-02-03 Oil and filter, power steering, replace
64570-1 6453-01-01-01 Servo pump, remove
64572-1 6453-02-01-01 Servo pump, install
77101-2 7710-03-02-01 Spoke wheel, replace
77102-2 7710-03-02-02 Disc wheel, replace
77103-3 7710-06-03-01 Disc wheel, check
77333-4 7735-03-04-01 Front wheel bearing, wear ring and sealing ring, replace 1
77333-4 7735-03-04-01 Front wheel bearing, wear ring and sealing ring, replace 2
77334-2 7736-05-02-01 Rear wheel bearing, adjust (one wheel)
77342-2 7735-05-02-03 Front wheel bearing, adjust (one wheel) 1
77342-2 7735-05-02-03 Front wheel bearing, adjust (one wheel) 2
77342-2 7735-05-02-03 Front wheel bearing, adjust (one wheel)
77343-3 7734-03-03-01 Wheelstud, replace
77356-5 7734-03-05-01 Wheel stud, replace (others each)
77363-2 7736-03-02-02 Rear wheel bearing and seal, replace 1
77363-2 7736-03-02-02 Rear wheel bearing and seal, replace 2
77365-3 7731-01-03-01 Front wheel hub, remove 1
77365-3 7731-01-03-01 Front wheel hub, remove 2
77365-3 7731-01-03-01 Front wheel hub, remove 3
77371-3 7731-02-03-01 Front wheel hub, install 1
77371-3 7731-02-03-01 Front wheel hub, install 2
87520-3 8759-03-03-06 Flame indicator, replace
87521-3 8759-03-03-07 Seals, heat exchanger, replace
87522-3 8759-03-03-08 Seals, fan, replace
87525-3 8755-03-03-01 Ignition electrodes, replace
87526-3 8759-03-03-09 Glow plug strainer, replace
87527-3 8754-03-03-01 Circuit board, replace
87528-3 8759-03-03-10 Discharge cap, replace
87530-3 8759-03-03-11 Casing cover, replace
87531-3 8759-03-03-12 Overheating breaker, replace
87578-2 8759-06-02-01 Carbon dioxide content, check and adjust 1
87578-2 8759-06-02-01 Carbon dioxide content, check and adjust
9992876 Spacer sleeve
Adjusting diff. lock indication
Adjustment of the final drive
Air drier non return valve, replace 56136-2
Air drier, drier insert, replace 56126-2
Air drier, overhaul. Removed 56117-4
Air drier, replace 56116-2
Balancing the propeller shaft 1
Balancing the propeller shaft 2
Balancing the propeller shaft 3
Balancing the propeller shaft 4
Balancing the propeller shaft 5
Balancing the propeller shaft 6
Balancing the propeller shaft 7
Balancing the propeller shaft 8
Basic housing
BATTERY ANALYSER 9812515
Battery analyser, 7200, user manual
Battery charging
Battery troubleshooting
Battery, warranty claim handling, additional information
Battery
Before check-measuring
Brake caliper front wheel, replace. Wheel removed 51137-3
Brake caliper rear wheel, replace. Wheels removed 51237-3
Brake caliper Rear wheel
Brake caliper, inspection
Brake caliper, overhaul (one front wheel). Brake caliper removed
Brake caliper, overhaul (one rear wheel). Brake caliper removed 51235-3
Brake disc rear wheel, replace. Wheels removed 51245-3
Brake disc, front wheel, replace. Wheel removed 51145-3
Brake pads, replace (two front wheels). Wheels removed 51121-3
Brake pads, replace (two rear wheels). Wheel removed 51221-3
Cable repair, example
Cable, electrical motor, replace 27510-3
Cables and connectors, fault tracing
Carbon dioxide content, check and adjust 87578-2
Casing cover, replace 87530-3
Check of high pressure monitor
Checking and adjusting engine and gearbox incIinations
Circuit board, replace 87527-3
Cleaning the chassis before complete painting
Clutch cylinder, replace 41314-2 1
Clutch cylinder, replace 41314-2 2
Clutch plate, replace. Gearbox removed 41103-3 1
Clutch plate, replace. Gearbox removed 41103-3 2
Clutch plate, replace. Gearbox removed 41103-3 3
Clutch, adjust
Control housing, overhaul. Removed 43278-4
Control lever parking brake, overhaul. Removed 56371-4
Delivery pipes, replace (all) 23724-2
Diaphragm sleeve, adjust. Final drive removed 46803-3
Diaphragm spring
Diff lock, check and adjust disengage and engage position 46802-2
Differential carrier, install 46572-1 1
Differential carrier, install 46572-1 2
Differential carrier, overhaul. Removed 46571-4 1
Differential carrier, overhaul. Removed 46571-4 2
Differential carrier, overhaul. Removed 46571-4 3
Differential carrier, remove 46570-1 1
Differential carrier, remove 46570-1 2
Disc
Dual draw dual return fuel system troubleshooting
External cab components
Final drive 1
Final drive 2
Final drive in rear axle casing
Flame indicator, replace 87520-3
Flame indicator
Flashing code signals on controls (D1LC)
Flywheel housing run-out, check. Clutch removed 21235-3
Footbrake valve, overhaul. Valve removed 56373-4
Front axle complete, install. Excl. springs and bleeding 61272-1
Front axle member (removed), check measuring
Front axle
Front end wear, check 61002-2
Front hub, components
Front wheel bearing, adjust (one wheel) 1
Front wheel bearing, adjust (one wheel) 2
Front wheel bearing, adjust (one wheel) 3
Front wheel bearing, adjust (one wheel) 4
Front wheel bearing, wear ring and sealing ring, replace. Hub removed 77333-4 1
Front wheel bearing, wear ring and sealing ring, replace. Hub removed 77333-4 2
Front wheel bearing, wear ring and sealing ring, replace. Hub removed 77333-4 3
Front wheel bearing, wear ring and sealing ring, replace. Hub removed 77333-4 4
Front wheel hub FAT 5,0
Front wheel hub, install. Wheel and brake drum removed 77371-3 1
Front wheel hub, install. Wheel and brake drum removed 77371-3 3
Front wheel hub, install. Wheel and brake drum removed 77371-3 4
Front wheel hub, remove. Wheel and brake drum removed 77365-3 1
Front wheel hub, remove. Wheel and brake drum removed 77365-3 2
Front wheel hub, remove. Wheel and brake drum removed 77365-3 3
Front wheel hub, remove. Wheel and brake drum removed 77365-3 4
Fuel pump
Fuel tank strainer, clean and drain condensation water 23415-3
Gate interlock
Gearbox assembly
Gearbox dissassemble
Gearbox install
Gearbox remove
Gearbox, disassemble and inspect 43165-5
General instructions
Glow plug strainer, replace 87526-3
Glow plug
Heat exchanger
Hub
Hubs, tightening torques
Hydraulic pump, service
Hydraulic system, fault tracing
Hydraulic system, general
Hydrodynamic retarder
Ignition electrodes, replace 87525-3
Indicator light bulb, replace 35126-2
Input shaft, overhaul. Unit removed 43197-5
Intermediate shaft, overhaul. Unit removed 43181-5
Main shaft, overhaul. Unit removed 43173-5
Manual gearbox, warranty claim handling, additional information
Masking
Material recommendations
Modification of cable harness for new brake contacts or horn
Oil and filter, power steering, replace 64514-2
Output shaft sealing ring, replace 43130-2 1
Output shaft sealing ring, replace 43130-2
Overheating breaker, replace 87531-3
Paint damage
Paint faults
Painting plastic surfaces
Parking brake 1
Parking brake cylinder, replacing
Parking brake cylinder
Parking brake
Parking heater 1
Parking heater
Particulate filter, fault tracing
Personal protective equipment
Pinion sealing ring, replace 46514-2 1
Pinion sealing ring, replace 46514-2 2
Power pump, install 64572-1
Power pump, remove 64570-1
Power take-off 1
Power take-off, install 48172-1 2
Power take-off, overhaul. Removed 48171-4 2
Power take-off, remove 48170-1 3
Power take-off
Pressure point, steering gear, check and adjust 64252-2
Preventive maintenance intervals
Priming
Principles
Propeller shaft 1
Propeller shaft
Pulling clutch, single disc
R3 - Group 431 432
R3 - Group 431 432-1
R3 - Group 431
R3 - Group 431-1
R3 - Group 460 465 466 468
R3 - Group 460 465 466 468-1
R3 - Group 460
R3 - Group 460-1
R3 - Group 593
R3 - Group 611
R3 - Group 640
R3 - Group 641
R3 - Group 852
R3 - Group 1750
Radiator, external cleaning 26106-2
Range cylinder, overhaul 43266-2
Range gear, overhaul. Unit removed 43175-5
Rear axle housing, venting -0
Rear axle parts
Rear hub, components
Rear wheel bearing and seal, replace 77363-2
Rear wheel bearing, adjust (one wheel) 77334-2 1
Rear wheel bearing, adjust (one wheel) 77334-2 2
Repairs to steel panels and paint damage
Sanding (rubbing down)
Sealing ring, steering spindle, replace 64210-2
Seals, fan, replace 87522-3
Seals, heat exchanger, replace 87521-3
Sensor, ambient air temperature
Servo pump
Shift unit, differential lock, overhaul 46534-5
Single disc clutch
Spacer ring, possible combinations
Speed sensor with O-ring
Starter motor, replace 33104-0
Steering gear, remove 64282-1
Steering gear
Steering knuckle, exploded view 1
Steering knuckle, exploded view 2
Steering knuckle, exploded view 3
Steering knuckle, overhaul (one). Hub removed 61103-3
Steering shaft bearings upper and lower, replace 64106-2
Steering wheel, replace 64104-2
Steering wheel, steering shaft and steering shaft adjustment
Straps
Surface treatment of chassis components
Symbol index
Test instrument for checking speed limiter, range inhibitor, cruise control and the tachograph's speedometer
The heater's output variations in relation to temperature
The pressure monitor's cut-off values
Thermostats, test. Removed 1-3 26273-4
Throw-out bearing, pulling clutch replace. Clutch removed 41283-5
Tightening torque 5
Tightening torques 1
Tightening torques 2
Tightening torques 3
Tightening torques 4
Tightening torques
Toe-in, adjust 60131-3
Toe-in, check 60124-2
Topcoating
Trailer brake control, overhaul. Removed 57106-4
Trailer connection, replace 37130-2
Tyre and inner tube
Universal joint angles – adjustment 6
Universal joint angles – adjustment 7
Universal joint angles, check and calculate 45122-2 1
Valve seat, replace (one) 21105-5
Washing, polishing and waxing, cab
Welding requirements
Wheel alignment 1
Wheel alignment
Wheel angles, check-measure (all) 60110-2 1
Wheel angles, check-measure (all) 60110-2 2
Wheel angles, check-measure (all) 60110-2 3
Wheel stud, replace (others each). Hub removed 77356-5
Wheel
Wheelstud, replace. Wheel and drum removed 77343-3
Working with chemicals