Maintenance service

AP00.20-D-0011BA

Maintenance service

16.7.09

Performed 



Input condition 

not OK 

Operation

Position no..



SERVICE SHEET for special equipment

Model 902.6, 903.6, 904.6 with engine 111.984 with code MZ7 Liquified Petrol Gas (LPG) drive

Model 902.6, 903.6, 904.6 with engine 111.984 with code MS7 NGT (Natural Gas Transporter) Sprinter

AP00.20-D-1209A

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-D-0101A

Lubricating work



Trailer hitch,

Dumper system

AP00.20-D-0020A

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



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, transfer case, front axle, rear axle, steering and power steering pump



AP00.20-D-0050A



All lines and hoses, sensor cables



AP00.20-D-0051A



Rubber boots for front axle supporting joints, rubber boots for front axle drive shafts, shock absorbers, axle-load-dependent brake force regulator



AP00.20-D-0052A



Check auxiliary rubber springs



AP32.00-D-3250A



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
corrosion protection/antifreeze, correct if necessary



______°C

Correct subject to a separate repair order.

AP20.00-D-2010A



Hydraulic Brake System



AP42.50-D-4210A



Power steering



AP46.00-D-4611A



Battery



AP54.10-D-5410A



Windshield washer system



AP82.35-D-8210A

Engine:



Replace spark plugs

Engine 111.984

AP15.10-D-1580A



Replace fuel filter

Engine 111.984

AP47.20-D-0780A

Engine 611, 612 except code KL5 Fuel filter with water separator

AP47.20-D-0780D

Engine 611, 612 with code KL5 Fuel filter with water separator

AP47.20-D-0780E



Air filter element:
Check fouling
(air filter with maintenance indicator)



If contaminated, replace air filter element - against separate job.

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

Paper element replaced  Yes  No

AP09.10-D-0951A

Chassis and body



Trailer hitch:
Check function, play and fixing



AP31.10-D-3151A



Dumper system:
Check function, play and attachment



AP55.20-D-5550A



Box-body:
check riveted joints for body at frame



Model 903.612/613 with code Z22 Post freight delivery service

Model 903.612/613 with code PG3 Integral box body with shelf system

Model 903.612/613 with code PG4 Integral box body without shelf system

Model 903.612 with code PG5 Integral box body UPS

AP60.40-D-6050A

Wheels, brakes



Tire inflation pressure:
Correct, including spare tire



AP40.15-D-4060A



Check brake lining thickness

Model 901, 902, 903, 904 

AP42.10-D-4253A

Model 905 

AP42.10-D-4253B

Approx. remaining brake lining thickness in mm:

left front right front

left rear right rear



Check parking brake



 Readjust subject to separate invoice.



Compressed-air reservoir:

Drain condensation

Model 905

AP42.60-D-4390A

maintenance indicator



Reset ASSYST maintenance computer

with code JW6 Service processor (ASSYST)

 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

 Z2

Manual transmission: oil change

Transmission 711.6

AP26.00-D-2601A

Transmission 716.6

 Once at 2nd maintenance service.

AP26.00-D-2601B

 Z2

Transfer case: oil change

AP28.00-D-2801A

 Z2

Front axle oil change

AP33.00-D-3301A

Engine:

 Z2

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

 Z2

Check poly-V belt for wear and damage



AP13.22-D-1351A

Additional operations at every

6th maintenance service

Oil service

 Z6

Rear axle: oil change

Model 901, 902 with rear axle 741.407

Model 903 with rear axle 741.408/409

Model 904 with rear axle 741.130

Model 905 with rear axle 741.980

AP35.00-D-3501A

Maintenance operations once a year

Oil service

 J1

Dumper system: oil change

AP55.20-D-5501A

Chassis and body

 J1

Replace dust filter for heating/air conditioning

AP83.00-D-8381A

Maintenance work every 2 years

 J2

Hydraulic brake system:
replace brake fluid

AP42.50-D-4280A

 J2

Compressed air drier:

Replace granulate cartridge

Model 905

AP42.60-D-4381A

Maintenance operations every

10 years/300,000 km

Oil service

 J10

Manual transmission

Transmission 716.643 in model 901.6, 902.6, 903.6, 904.6

 Sprint shift transmission (SSG).

AP26.00-D-2601B

Maintenance operations every

15 years/250,000 km

 J15

Replace coolant

 Pay attention to coolant composition!

AP20.00-D-2080A