IMPACT 4.02.

11 06/06/17

Chassis ID Path
JPCT 10004 1770/Service and maintenance//Basic service

Model Identity
UD-HDE 136604465

Publish date ID/Operation

22/01/16 17744-2

17744-2 Basic service

Note: Regarding chassis lubrication and oil intervals, refer the Service Publications for Function group 175 Preventive
maintenance intervals .

When carrying out oil changes, it is extremely important that as much oil as possible to be drained from the component
and replaced. For this reason, it is best to drain the oil immediately after driving, i.e., when the oil is hot, it is able to
flow easily.

Replace the oil filters when the oil is changed. Old oil filters must always be discarded. Always check the oil level after
filling up.

Warning
Hot oil can cause burns. Use safety gloves.

For information on oil change volumes, oil and grease quality, viscosity and change intervals, refer the Service
Publications for Function group 175 Preventive maintenance intervals .

For the record sheet, seeBasic service

Chassis lubrication
1
Refer the Service Publications for Function group 175 Preventive maintenance intervals to confirm the chassis
lubrication interval. If the lubrication interval coincides with the basic service interval, refer the Service Publications for
Function group 175 Lubrication chart .

Cab lubrication
1
Refer the Service Publications for Function group 175 Preventive maintenance intervals to confirm the cab lubrication
interval. If the lubrication interval coincides with the basic service interval, refer the Service Publications for Function
group 175 Lubrication chart .

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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IMPACT 4.02.11 06/06/17

Check oil level in the engine

1

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.02.11 06/06/17

Note: Under no circumstances oil level must not be below the lower mark on the dipstick. The oil level must not be
above the upper mark on the dipstick either.

Check that the oil level is in the upper half of the area between the MAX and MIN marks on the dipstick.
Run the engine and check that there are no oil leaks.
Switch off the engine, wait for few minutes and check the oil level. Top up, if necessary.

2
Refer the Service Publications for Function group 175 Preventive maintenance intervals to confirm the engine oil
change interval. If the oil change interval coincides with the basic service interval, see Additional services, op. no.
17513-2.

Check fluid level in the clutch fluid tank

1

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.02.11 06/06/17

Check the level of fluid in the clutch fluid tank is half-way up the tank or between the MIN and MAX marks
(where such marks exist).
Top up if necessary.

Take care when adding fluid. Check the cap on the fluid tank is closed properly so that no fluid spills out and
damages the paintwork.

Note: It is important, that the fluid is of the correct quality. Refer the Service Publication for Function group 175
Preventive maintenance intervals .
Cleanliness is important when adding clutch fluid. The containers used to fill the tank must be completely clean
and free from any trace of dirt or any kind of grease or mineral oil.

Check coolant level

1

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IMPACT 4.02.11 06/06/17

Note: If you need to change the coolant, regardless of the change interval, see Additional services, op. no. 26010–2.

If necessary, top up the cooling system with 60% of water and 40% of concentrated coolant (mix before adding).
The fluid level must be between the MIN and MAX marks on the expansion tank when the engine is cold.

For information on water and coolant quality, refer the Service Publications for Function group 175 Preventive
maintenance intervals .

Check water level in the windscreen washer tank.

1

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IMPACT 4.02.11 06/06/17

Fill up the windscreen washer tanks with water if necessary

Check air drier

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IMPACT 4.02.11 06/06/17

Note: If the air drier has to be changed depending on service intervals, refer to Additional services Additional services,
op. no. 56126–2.

For information on air drier service intervals, refer the Service Publication for Function group 175 Preventive
maintenance intervals .

Caution
Follow the instructions carefully to avoid personal injury and damage to the product or the equipment.

Note: Check that the parking brake is applied.

Drain the condensed water that has accumulated in the compressed air tanks.
In vehicles equipped with air driers, there must not be any condensed water in the compressed air tanks.

The absence of condensed water in the compressed air tanks means that the air drier is functioning correctly.

Drain the compressed air tanks and check that the pressure regulator restarts. Start the engine and check there
is no air is leakage from the silencer in the air drier when the compressor is charging.

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IMPACT 4.02.11 06/06/17

If there is an air leak in the air drier silencer, use the Function group 56 Service Publications as a guide to
repairing the air drier.

Drain the air from the compressed air system using nipple 9992976 .

Checks inside the cab

Check control and warning lamps

Instrument panel display

The engine must be switched off and the ignition key must be in the driving position.

1. Adblue
2. Battery
3. Speedometer
4. Display screen
5. Tell tale indicators
6. Tachometer
7. Parking brake
8. Trailer ABS
9. Tractor ABS
10. Engine coolant temperature gauge
11. Transmission high
12. Enter button
13. Next button
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14. the Volvo Group
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IMPACT 4.02.11 06/06/17

14. Previous button

15. Escape button
16. Transmission low
17. Low fuel
18. Differential lock
19. Inter axle lock

Check vehicle control unit fault codes

1

During the tests, the engine must be switched off and the ignition key must be in the driving position.

Use the control buttons on the instrument cluster to access the information and check any fault code that appears on
the display on the instrument panel.

With the help of the control buttons on the instrument cluster, access the fault codes in the display menu that
might be stored on any one of the vehicle control units.
Note down any fault codes and then repair the corresponding faults.
Use tech tool to reset the fault codes after repairing them.

Fault codes can also be read with a diagnostic computer using the communication socket located under the
instrument panel on the driver's side.

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IMPACT 4.02.11 06/06/17

Use the Function group 03 Service Publications as a guide.

Check service brake sealing

1

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IMPACT 4.02.11 06/06/17

A – Adapter
B – Air gauge

Charge the pneumatic system.

Turn off the engine
The ignition key must be in drive position.
The parking brake must e released.
Connect the manometer and its accessories to tank. Use tools 9996926 (air gauge) and 9992976 (adapter)
Prepare the vehicle for the test

Note: Before checking the pressure the vehicle must be rested for few minutes.

Press the brake pedal with full pressure.

Check the pressure drop in gauge. It must not exceed 20 kPa (0.2 bar) for a period of 5 minutes.
Check around the vehicle for all possible air leak.
Disconnect the adapter and pressure gauge from the air tank.

External checks

Check lights and reflectors

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IMPACT 4.02.11 06/06/17

A Headlamp adjustment

B Front fog lamp switch

C Rear fog lamp switch

1 Position 0

2 Parking lights

3 Headlamps

Check all the external lamps.

Check that all of the lenses in the lamps are in good condition.
Check that the reflectors are in good condition and that none of the reflectors is missing.

Check condition of the wipers and washers

1

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IMPACT 4.02.11 06/06/17

A Off position

B Intermittent

C Low

D High

Washer
Washer will be control by a push button at the end of the stalk; it includes one rest position and one momentary active
position

Adjust headlamps
1

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IMPACT 4.02.11 06/06/17

Check that the bogie is lowered.

Vehicles equipped with automatic headlamp adjustment: Check that the headlamp light adjustment switch is in
the 0 position.
Check the condition of the glass and the headlamp reflectors.
Use a headlamp alignment instrument to check that the full and dipped beam lights are correctly adjusted.
Check the adjustment of the fog lamps and/or the spot lamp, if fitted.
Check the luminosity.
If necessary, correct the adjustment of the head lamps.

Check air intake and air deflector

1

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IMPACT 4.02.11 06/06/17

Visually check that the intake pipe is in good condition and that good sealing exists between the rubber bellows
and the pipe leading from the air filter housing.
Check the bracket attachments, rubber supports and bolted joints on the air intake and the air deflector.
Check that there are no cracks in the air deflector or in the deflector attachment brackets.

Check battery attachments, connections and electrolyte levels

1

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IMPACT 4.02.11 06/06/17

Warning
The batteries contain sulphuric acid, which is corrosive.
Use goggles when carrying out maintenance work on the batteries.

Check that the batteries are not dirty.

Check that the batteries are not leaking.
Check that the batteries are firmly attached.

Note: Excessively tightening the attachment brackets could damage the batteries.

Check the condition of the batteries using battery tester 88890075.

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IMPACT 4.02.11 06/06/17

Check that the level of electrolyte in the battery cells is approximately 18–28 mm above the cell plates.
If necessary, add distilled water: no more than 28 mm above the plates.

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IMPACT 4.02.11 06/06/17

Check that the battery poles are not corroded or damaged.

If necessary, clean and lubricate the battery cable terminals.

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IMPACT 4.02.11 06/06/17

Check that the cables are properly insulated and correctly positioned.
Check the attachment points of all of the ground cables.
Check that the ground cables leading from the negative battery terminal to the engine support are unbroken and
in good condition.

Safety norms for battery charging

Always wear safety goggles.

Remove the caps from all of the cells and place them on top of their respective holes.
Switch off the main switch (if installed).
Disconnect at least one of the battery cables. (Some control units receive a voltage supply directly from the
batteries). Quick-charge chargers can generate very high voltages which could damage electronic equipment.
Charge the batteries in a well-ventilated place.
Smoking is not permitted. Avoid flames and electrical sparks in the surrounding area as explosive gases are
released when batteries are charged.
The cable clips must be connected/disconnected from the battery terminals when the charger is switched off.

Caution
Follow the instructions carefully to avoid personal injury and damage to the equipment.

For more information on batteries and battery charging, consult the Group 31 Service Publications entitled
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IMPACT 4.02.11 06/06/17

Batteries.

Check fuel tanks, hoses, connecting pipes and straps on the tanks
1

Check that there are no cracks or leaks in the tank.

Check that the straps on the tanks are not loose or broken.
Check that the pipes, hoses and electric cables leading from the combined tank unit are firmly attached. Also
check for leaks and ensure that the pipes, hoses and cables are not rubbing against anything.

Check fuel tank air vent filter

1

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IMPACT 4.02.11 06/06/17

Note: If the fuel tank ventilation filter has to be changed, depending on the filter service interval, please refer to
Additional services, op. no. 23414–3, 23306–3, 23311–3.

Check that the air inlet in the filter is not blocked by dirt or dust.
Check that the air vent pipe and filter are in good condition and firmly secured.

For information on the filter service interval, refer the Service Publication for Function group 175 Preventive
maintenance intervals .

Fuel tank drainage

1

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IMPACT 4.02.11 06/06/17

Place a container under the plug in the fuel tank.

Loosen the drain plug a few times until the water and residue deposited at the bottom of the tank start to flow out
through the drain hole.

Note: Do not loosen the plug completely. If this is done, the fuel tank will empty.

Tighten the drain plug when clean fuel starts to flow out.

Engine compartment
Note: If sound insulation is installed to the chassis and under the engine, make sure to remove it.

Check oil level in the power steering system

1

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IMPACT 4.02.11 06/06/17

Clean around the cap and the dipstick.

Check the oil level. When the engine is switched off, the oil level must reach the MAX mark on the dipstick.
Top up the oil level, if necessary.

Check of alternator attachment, electrical connections and cab grounding

1

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IMPACT 4.02.11 06/06/17

Note: If the carbon brush has to be changed depending on service intervals, refer to Additional servicesAdditional
services, op. no. 32126–3.

Check the alternator bracket.

Check that the electrical terminals on the alternator are properly secured.
Check that the ground cables between the cab and the engine block are unbroken and in good condition.

For information on the service interval for the carbon brushes, refer the Service Publication for Function group 175
Preventive maintenance intervals check clutch.

Check drive belts and belt tensioners

1

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IMPACT 4.02.11 06/06/17

Note: If the maintenance interval calls for the multi-V drive belt and tensioner to be changed, please refer to Additional
services, op. no. 26304–2, 26308–3 and 32123–3.

Check that none of the grooves in the belt is missing.

Check that the belts are not cracked. Cracked belts must be replaced.
There must not be any dirt or grease on the belts or the contact surfaces of the belt pulley.
Check the automatic belt tensioner.

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IMPACT 4.02.11 06/06/17

1. Check that the belt tensioner works.

2. Use a lever to alleviate the tension in the belt tensioner and inspect the roller bearings in the tensioner
and all of the support rollers.

For information on change intervals for multi-grooved belts, refer the Service Publication for Function group 175
Preventive maintenance intervals .

Check front engine supporting pads

1

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IMPACT 4.02.11 06/06/17

Check the rubber pads are in good condition.

Check the brackets are in good condition and properly tightened.

Check tightness of engine mount and air compressor

1

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IMPACT 4.02.11 06/06/17

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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IMPACT 4.02.11 06/06/17

Check there is no oil or coolant leaks on the engine.

Check the pipe joins, hose joins and flanges are not leaking.
Check the pipes and the hoses are not cracked or rubbing against any other parts.
Check the engine-driven power take-off and the pipes are not leaking.
Check the compressor is not leaking.

Check fuel pipes and lines

1

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IMPACT 4.02.11 06/06/17

Check the pipe and the hose connections on the fuel lines are not leaking.
Check the fuel pipes are not leaking or rubbing against any other parts.

Check for exhaust leakage

1

Exhaust gas leaks are detected by the presence of soot.

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IMPACT 4.02.11 06/06/17

Check the exhaust outlets in the cylinder heads, the junctions and the flanges on the exhaust manifold for
exhaust gas leaks.
Check for exhaust gas leaks in the exhaust gas pressure regulator, the exhaust brake and the joint clamps on
the front exhaust pipe.

Check hoses and pipes for the intercooler

1

Check the pipes and hoses between the intercooler and the engine are in good condition and are not rubbing
against any other object.
Check the clamps and bolts in the pipes and hoses between the engine and the intercooler.
Check the tightening torque applied to the clamps on the pipes and hoses between the engine and the
intercooler.

Check engine sound insulation

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IMPACT 4.02.11 06/06/17

1. Noise shield under the cab

2. Noise shield engine side
3. Noise shield behind cab
4. Noise shield under engine

The sound insulation located under the cab must be inspected to check that it is in good working condition. This also
applies to its attachment.
If you notice that the component has suffered any deformation or deterioration, or if the attachments have loosened or
come free, the component and/or its attachments must be changed. If this is not done and the vehicle is used in this
condition, the vehicle and/or third parties could be damaged.

Warning
In the event that work needs to be carried out on components located near the sound insulation, the sound
insulation must not be contaminated or damaged. If it is, and the vehicle is used in this condition, damage may
occur to the vehicle or to third parties.

Front suspension and steering

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IMPACT 4.02.11 06/06/17

Check tyre wear

1

Check that tyre wear is normal.

Note: Make a note of any observations in the record sheet!

Front tyres

Check the front tyres for rounded wear, which indicates problems in wheel bearings with very high clearance,
problems with axle bearings, or the lack of an inertia point at the centre of the steering gear.
Check the tyres on the front wheels for lateral wear (chafed edge), which indicates toe-in problems
Check the front wheel tyres for abnormal wear on one side of the tyre, which indicates camber problems.

Rear tyres

Check the rear wheel tyres for irregular wear at the edges of the treads. This could be the result of incorrectly
combined tyres in a twin mounting.
Check for visible signs of wear on tyres belonging to wheel pairs and check if they are rubbing against each
other. Take note of any friction marks.
Check for a tendency to wear caused by incorrect toe-in, which could be the result of a misaligned axle.

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IMPACT 4.02.11 06/06/17

Spare wheel tyre

Check the condition of the spare wheel.

Check universal joint on the steering shaft and the power steering hoses and pipes
1

Check that the join between the steering shaft and the steering gear is firmly attached and free from any
clearance.
Check that the power steering hoses and pipes are not damaged and are not rubbing against any other part.

Check gaiters and ball joint play

Danger
It is important to observe all of the instructions contained in this item in order to avoid any possible accidents
caused by inadequate maintenance.

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IMPACT 4.02.11 06/06/17

Danger
Never weld steering system components.

Note: The components must be cleaned. Do not use solvents to carry out this cleaning. Use only a cotton wipe or a
clean cloth.
When cleaning, take care not to damage the protective rubbers on the ball joints.

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IMPACT 4.02.11 06/06/17

1. Ball joint
2. Clamp
3. Link rod or track rod

Turn the steering wheel from one side to the other and check its clearance, attachment and the condition of its
components. Check the attachment of the link rod connected to the axle (with or without activating the hydraulic
system).
When turning the steering wheel to full lock, there must be no relative movement between the link rod or track
rod and the ball joint.

Note: If there is relative movement between any of the components, the whole rod (link rod or track rod and ball
joint) must be replaced.

Check the thread of the ball joint for rust. None of the components must show any signs of rust, denting or
damage. If rust is found, the whole rod (link rod or track rod and ball joint) must be replaced.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.02.11 06/06/17

A. Pitman arm
B. Link rod
C. Intermediate steering arm
D. Steering arm
E. Track rod

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IMPACT 4.02.11 06/06/17

Clamp position

Check that there is no clearance in the intermediate steering arm and the hydraulic cylinder attachments on twin
front axles.
Check the attachments on the steering arm, link rod and track rod, and check that the clamps are not damaged
and are properly tightened.

Note: Neither the bolt in the clamp nor the clamp itself must be deformed in any way. If any deformation is
found, replace the components with new genuine parts.

The clamp nut must be torque tightened to 80 ± 10 Nm for M12 bolts and to 170 ± 10 Nm for M14 bolts.
At least three threads on the bolt must show beyond the nut and the clamp must be positioned in accordance
with the illustration.

Caution
In the event that intervention is required with respect to the clamp and/or clamp bolt, replace the bolt and
the attachment nut with new genuine parts.

Check that the Pitman arm connected to the steering gear is firmly attached, and that the nut is tightened and
correctly locked.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.02.11 06/06/17

Check the attachment between the steering gear and the bracket and chassis frame, ensuring that there are no
cracks or loose bolted joins.
Check the attachments on the intermediate steering arm and the hydraulic cylinders, ensuring that they are not
cracked, that there is no clearance and that the bolted junctions are not loose.

Check that the rubber boots on the ball joints on the link rod, the track rod, the steering arm, the extra hydraulic
cylinder are in good condition and sealing correctly.

If any of the gaiters is cracked or damaged, the ball joint must be replaced.

Note: A cracked or damaged gaiters will significantly reduce the working life of the ball joint.

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IMPACT 4.02.11 06/06/17

Position the wheels in a straight line. A ball joint which shows signs of wear has a large amount of clearance in
this position.
Check the clearance and attachment of all of the ball joints in the steering system.
Position the dial gauge 9808092 and the magnetic bracket 9812528 .
Press the ball joint together with to its inner end position using Polygrip pliers. Set the dial gauge to zero.
Spread the ball joint as much as possible using lever 9998511 .
There should be no axial play.

If there is any play for more than 2 mm, the ball joint must be replaced.

Check front shock absorbers

1

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IMPACT 4.02.11 06/06/17

Check the rubber bushings.

Check the shock absorber attachments.
Check the shock absorber brackets are in good condition and are properly attached.
Check the shock absorbers for oil leaks.

Check the kingpin bearings

1

Check the axial clearance between the kingpin and the shaft (A) on both sides.
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IMPACT 4.02.11 06/06/17

When the axial clearance is measured, the vehicle must be stationary on a flat surface in such a way that there
is a load on the kingpin bearing.
Use a feeler gauge to measure the clearance between the kingpin and axle.

For information on the value permitted (A) for the axial clearance, depending on the type of axle, refer Additional
services, op. no. 61101–2.

Check the radial clearance in the kingpin bushing on both sides.

1. Lift the vehicle from under the axle.

2. With the help of an appropriate support or an assistant, apply the service brake in such a way that the clearance
in the wheel bearings does not affect the measurement.
3. Check the clearance in the kingpin bushing, using a rod in the hole in the wheel as a lever with which to lift it.

For information on the radial clearance permitted in the kingpin bushing, depending on the type of axle, refer
Additional services, op. no. 61101–2.

In case of doubt over the measurement of the radial clearance in the kingpin bushing, use one of the following
methods to determine the real axial clearance measurement.

Measuring the radial clearance in the kingpin bushing with a dial indicator

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IMPACT 4.02.11 06/06/17

Place a dial indicator with a magnetic stand on the front axle so that it is touching the lower part near the kingpin
bushing.
Use a rod as a lever to lift the axle and check the radial clearance in the bushing on the dial indicator.

For information on the radial clearance permitted in the kingpin bushing, depending on the type of axle, refer
Additional services, op. no. 61101–2.

Measuring the radial clearance in the kingpin bushing on the tyre side

Lift the wheel, using a bar in the hole in the wheel as a lever.
Place a support, for example, a square, next to the tyre.

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IMPACT 4.02.11 06/06/17

Move the lever downwards. At the same time, precisely measure the distance between the support and the tyre.
The radial clearance measured at the measuring point will be greater than the maximum radial clearance
permitted in the bushing, which depends on the distance between the bushing and the side of the tyre.
Check the radial clearance of the kingpin bushings by using the distance measured and the corresponding table,
depending on the type of axle. See the Function group 6 Service Publications.

If there are some abnormal tyre wear, vehicle drifting and more clearance than specified for the kingpin, refer
Additional services, op. no. 61101-2 for wheel alignment check.

Check front and rear wheels disc and nuts torque

Front wheel
1

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IMPACT 4.02.11 06/06/17

Rear wheel
2

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IMPACT 4.02.11 06/06/17

Check the wheel disc for cracks and rust, which could indicate loose nuts or broken wheel bolts.

Check for wheel nut torques.

Checks underneath the vehicle

Check clutch connections

1

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IMPACT 4.02.11 06/06/17

Remove the sound insulation from underneath the gearbox

Check pneumatic and hydraulic connections of clutch servo for any leakage.

Check the sealing of the gearbox and power take-off

1

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IMPACT 4.02.11 06/06/17

Check the gearbox oil is not leaking.

Check the power take-off is not leaking oil.
Install the sound insulation, if equipped.
If there is a leak, check the oil level.

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IMPACT 4.02.11 06/06/17

Check propeller shafts – universal joints, sliding joints and support bearings
1

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IMPACT 4.02.11 06/06/17

With the gearbox in the neutral position, check the propeller shaft for runout or any other type of damage.
Visually check that the attachment bolts in the support bearings and flanges are tightened. Also check that the
lock rings are in the correct position.
If the propeller shaft is lubricated, lubricate all of the points in accordance with the lubrication chart, refer the
Service Publications for Function group 175 Lubrication chart .

Any wear suffered by the sides and tops of the grooves could give rise to movement in the sliding joint which
could lead to vibration and unbalancing. No value has been defined for this clearance. However, it must be
observed and noted down so that the situation can be explained to the customer.

Check the attachment of the support bearing bracket and the condition of the rubber pads. There must not be
any clearance between the rubber and the bracket.

Check sealing of rear axle and hub reduction gear

1

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IMPACT 4.02.11 06/06/17

1. Air vent
2. Filler plug (hub reduction)
3. Filler plug (rear axle)

Check for oil leak in the rear axle.

There could be a small film of oil on the air vent outlet in the rear axle. This is normal.

Check for oil leaks in the hub reduction gear.

Check air vent is not blocked.
If there is a leak, check the oil level.

Check exhaust pipe and silencer.

1

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IMPACT 4.02.11 06/06/17

Check the condition of the metal plate in the exhaust pipe and the silencer.
Check the flexible hoses and clamps.
Check the exhaust pipe bracket and the silencer, ensuring that there are no cracks in the brackets or bolts, and
make sure that the clamps and protection plates are not loose.

Check springs and "U" bolts

1

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IMPACT 4.02.11 06/06/17

Check to see if the springs are broken or the blades deformed, which could indicate that the central bolt is
broken.
Check front and rear "U" bolts. If they are loose, this means the leaf spring is not correctly compressed and/or
the leaf spring has moved in the attachment to the axle. Check the tightening torque,
The tightening torque must be 540±70 Nm for M20 bolts and 660±85 Nm for M24 bolts.

Check attachment of the spring cradle (6x2 Tandem / 6x4 / 8x4)

Check the tightening torque applied to the attachment bolts in the spring cradle in 6x2 Tandem, 6x4 and 8x4 vehicles.
The tightening torque must be 220±35 Nm for M16 bolts and 430±70 Nm for M20 bolts.

Check rear wheel bearings (drive axle)

1

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IMPACT 4.02.11 06/06/17

When the check is carried out, the rear of the vehicle must be raised and supported and the parking brake must be
released.

Check the clearance in the rear wheel bearings, using a rod in the hole in the wheel as a lever with which to lift
it. The bearings must normally be preloaded. For this reason, there must not be any clearance in the wheel
bearings.

However, in certain cases there could be a clearance of up to 0.1 mm in the bearing.

If there is clearance in the bearings, this clearance must be measured using a dial indicator.

Note: Note down the clearance in the bearing!

1. If the clearance in the bearing is less than 0.1 mm: turn the wheel with a wheel-turning device. The drive
shaft must be removed from the drive wheel hubs. Listen for any abnormal noise in the bearings when
they are being turned.

The front and rear auxiliary wheel bearings must always be checked using a wheel-turning device.

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IMPACT 4.02.11 06/06/17

Note: Make a note of any abnormal noise in the rear wheel bearings.

Abnormal noise in the bearings is a sign that the bearing has suffered wear. The hub bearings must be
replaced.

2. If the clearance in the bearing is 0.1 mm or more, the hub bearings must immediately be replaced to
avoid future damage.

Note: The clearance in the bearing cannot be adjusted.

For working procedures related to hubs, use the Function group 7 Service Publications as a guide.

Check brake linings

Drum brakes

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IMPACT 4.02.11 06/06/17

Check the thickness of the brake linings via the inspection holes in the support plates. The minimum permitted
thickness for the brake linings is 5 mm.
Check that no grease is leaking from the hubs onto the brake linings.

Note: Note down the thickness of the brake linings in the record sheet!

Refer the Function group 5 Service Publications as a guide when carrying out maintenance work on the brake
system.

Check brake cylinders, levers and forks

1

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IMPACT 4.02.11 06/06/17

Check brake lever travel

1

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IMPACT 4.02.11 06/06/17

The functioning of the automatic adjustment mechanism is checked by measuring the brake lever stroke, C.

The check is carried out when the braking pressure is 7.5 bar.

The wheels must be blocked to prevent the vehicle from moving.

Release the parking brake and use a lever or an assistant to activate the service brake.
Measure the distance b.
Release the service brake and measure the distance a.
Calculate the braking stroke, C (C= b-a).

Note: Note down the values in the record sheet!

The stroke of brake lever C must never exceed 52 mm at 7.5 bar with automatic adjustment. The minimum lever stroke
at a pressure of 7.5 bar is 17 mm . The difference between the lever strokes on the same axle must never exceed 5
mm.

Nominal lever stroke values with automatic adjustment

A B C

24 inches 170 mm 45 - 52 mm

27 inches 170 mm 45 - 52 mm
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IMPACT 4.02.11 06/06/17

A = size of the brake cylinder in square inches.

B = length of the auto slack adjuster in mm

C = nominal value of operating stroke length (when the brakes are cold).

Check axial play of high mounted brake cylinder

Check the axial play of high mounted brake cylinder at every service.
Axial play of slack adjuster/ brake cam A = 0.8 to 1.2 mm

Check alignment of the trailing axle or the second drive axle

Note: When checking the alignment of the trailing axle or the second drive axle, the first drive axle is used as a
reference, which must be borne in mind in case there is any doubt concerning the alignment of the first drive axle in
relation to the front axle. The alignment of the first drive axle with the front axle must be checked first before the
alignment of the trailing axle or the second drive axle is checked.

1. Block the front wheels and release the parking brake.

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IMPACT 4.02.11 06/06/17

2. Check that distances A and B are the same by using the alignment device compass, positioning it in the recess
in the centre of the first drive axle hub and in the recess in the centre of the trailing axle hub or the second drive
axle hub.
3. The difference between distances A and B must not be greater than 1.5 mm.

If the difference between the distances is outside the specified limit, adjust the trailing axle or the second drive axle in
accordance with Additional services , op. no. 65561–3.

Driving test
This is a short driving test, the aim of which is to evaluate a number of points.

Note: Use the Driver's Manual as an aid.

Checks after starting the engine

1

Check that the longitudinal position and the height of the steering wheel can be adjusted. Check that the
steering wheel is locked in the adjusted position.
Check that all of the control and warning lamps, and the instruments, are working.
The oil pressure, alternator charging and OBD warning lamps should go out as soon as the engine is started.
Check that the engine oil pressure gauge shows oil pressure.
The symbol or the warning lamp which indicates that the coolant is low must switch off.
The symbol or warning lamp that indicates that the cab is locked must be switched off, which indicates that the
cab is properly locked.
The service brake warning lamps must switch off when the compressed air system is charged.
The parking brake warning lamp must light up when the parking brake is applied.
The ABS brake control lamp must light up.

Check during road test

1
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IMPACT 4.02.11 06/06/17

Check the speedometer, odometer and the other instruments are working.
The brake system pressure gauges must be displaying values which lie inside the normal range.
Check that the steering works satisfactorily and is not unbalanced.
Check that the brakes work correctly and do not pull to one side or lock.
Check that the engine brake works correctly.
Check for exhaust gas leaks when the vehicle is loaded.
Check the ABS control lamp switches off. If the lamp does not switch off, or if it switches off and lights up again,
there is a fault in the system.
Check the blocked air filter warning lamp or symbol do not light up when driving.
Check the clutch and the gearbox are working correctly.
Check the differential lock activation, plus the corresponding control lamps, are working.
Check on-board computer display on the instrument panel is not showing any fault code. If there is a fault,
correct it and delete the fault code!
Check operating temperature of the engine (minimum 75°C).
When driving, check that the windscreen wiper works and that it cleans the correct area.
When driving, check windscreen washer works and that the water jets reach the glass as expected.

Checks carried out after the driving test

1

Check the parking brake works by carefully trying to move the vehicle with the parking brake applied.
Listen out for any abnormal noise coming from the engine compartment.
Check that there are no leaks in the exhaust pipe and silencer joins.
Check the display to ensure that no fault code is stored in the vehicle control units. If a fault is registered, correct
it and delete it. Refer the appropriate service information as a guide to repairing any fault code.
Check that there no oil leaks or leaks of any other fluid.

Finish
1

Clean the levers, the steering wheel and the controls.

Clean the mats in the cab.

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