Maintenance service

AP00.20-D-0011A

Maintenance service

16.7.09

Performed 



Input condition 

not OK 

Operation

Position no..

Check by customer service advisor



Check vehicle for damage to paintwork, corrosion and accident damage



Test bench



Brake testing on test stand



Enter brake values in kN:

Left Right

Front

Rear

Parking brake

AP42.00-D-4290A

Oil service



Engine:
Oil and filter change

AP18.00-S-0101A

Maintenance

Function/condition testing



Signaling system, indicator lamps



AP54.00-D-5451A



Headlamps, exterior lamps



AP82.10-D-8251A



Windshield wipers, windshield washer system, rear window wiper, headlamp cleaning system



AP82.30-D-8252A

Check for leaks and condition
Pay attention to chafing points and line routing!

In the event of any loss of fluid, determine cause and rectify, subject to separate repair order



All major assemblies:
engine, transmission, steering,
power steering pump



AP00.20-D-0050A



All lines and hoses, sensor cables



 Check brake hoses at fastening cams for damage.

AP00.20-D-0051A



Rubber sleeves for the front axle supporting joints, rubber sleeves for the drive shafts, shock absorbers, air-spring bellows, protective caps



AP00.20-D-0052A



Check steering mechanism: tie rod, drag link, rubber boots and protective caps



AP46.00-D-4650A

Check and correct fluid level



Check engine cooling system
anticorrosive/antifreeze, correct if necessary



______°C

Correct under separate order

AP20.00-D-2010A



Hydraulic Brake System



AP42.50-D-4210A



Power steering



AP46.00-D-4611A



Windshield washer system



AP82.35-D-8210A

Engine:



Air filter element:
check for soiling

(air filter with maintenance indicator)



Replace according to condition - against separate order

 Replace at least every 3 years. Note installation date, refer to confirmations in maintenance booklet!

Paper element replaced  Yes  No

AP09.10-D-0951B



Replace spark plugs

Engine 111

AP15.10-D-1580A

Engine 104.900 in model 638.244 /294

AP15.10-S-1580A



Replace fuel filter
(Filter without water separator)

Engine 611

AP47.20-D-0780D

Chassis and body



Trailer hitch with
detachable ball neck:
Clean after inspection
(as necessary)



AP31.11-D-3130A



Trailer hitch with
detachable ball neck
Lubricate and check for proper operation



AP31.11-D-3121A



Replace dust filter for heating/air conditioning

Left-hand drive vehicles

AP83.00-S-8381B

Right-hand drive vehicles

AP83.00-S-8381A

Wheels, brakes



Tire inflation pressure:
Correct, including spare tire



AP40.15-D-4060A



Check brake pads for lining thickness and condition of brake disks



Approx. remaining brake lining thickness in mm:

left front right front

left rear right rear

Depending on findings, replace brake pads and brake disks subject to a separate order.

AP42.10-D-4253A

maintenance indicator



Reset ASSYST maintenance computer

 Upon completion of the maintenance operations.

 Note set oil quality in maintenance computer, change if necessary.

AP00.20-D-0040A

Additional operations at every

2nd maintenance service

Oil service



Manual transmission: oil change

AP26.00-D-2601A

Engine:



Replace air filter element

(air filter without maintenance indicator)

 Replace at least every 3 years. Note installation date, refer to confirmations in maintenance booklet!

AP09.10-D-0980A



Check poly-V belt for wear and damage



AP13.22-D-1351B



Replace fuel prefilter

Engine 601

AP47.20-D-0781A



Replace fuel filter

Engine 104.900, 111

AP47.20-D-0780A

Engine 601

AP47.20-D-0780B

Engine 611

Additional operations at every

4th maintenance service



Automatic transmission: oil change

ZF 4 HP 20

 At least every 9 years.

AP27.00-D-2701A

Additional operations every 2 years



Hydraulic brake system:
replace brake fluid

AP42.50-D-4280A

Additional operations every 15 years or 250 000 km



Replace coolant

 Pay attention to coolant composition!

AP20.00-D-2080A