Service Manual

Buses
Section 0 (03)
Specifications B7R

TP 16073/1
 Foreword

The specification data in this Service Manual is based on

information available by December 1998. Volvo Bus Cor-
poration reserves the right to make specification changes after
the date of publication.

Contents

page
General ....................................................................... 1
Service and maintenance ............................................ 4
Engine ......................................................................... 7
Electrical system and instrumentation ........................ 15
Power transmission, rear axle ..................................... 16
Brakes ......................................................................... 22
Front suspension and steering .................................... 25
Frame, suspension and wheels ................................... 26

Order number: TP 16073/1

 General
Scope
This Specifications Manual relates to Volvo B7R bus
models with the following principal characteristics:
Wheelbases Engine types Gearbox types Rear axle types Wheel suspension types
32501 D7B2302 Volvo G8 EGS (Manual) EV 80 Air bellows “LUF”
5300 D7B2602 Volvo G8 MGS (Manual) EV 85 Parabolic leaf spring “BLF”
5500 D7A2852 ZF S6-85 (Manual)
6000 D7A2303 ZF 4HP 500 (Automatic)
6300 D7A2603 Voith D863.3 (Automatic)
D7A2803
1
Chassis transport wheelbase, to be extended by coachbuilder
2
Certified in accordance with EC Euro II regulations
3
Certified in accordance with US legislation

Weights
Buses with air suspension, and buses with
heavy-duty parabolic leaf spring suspension

Technical weights (kg)

Max. front axle load 6 500
Max. rear axle load 11 500
Max. GVW (Gross Vehicle Weight) 17 500

Buses with standard parabolic leaf spring

suspension
Max. front axle load 6 500
Max. rear axle load 10 000
Max. GVW (Gross Vehicle Weight) 16 500
The above weights are generally applicable, but national
deviations can occur. The vehicle’s documents (type
certificate) indicate the permitted weights for each bus
and the specified wheel/tyre combination. The choice of
wheels and tyres may limit the permitted loading.

Vehicle identification (VIN no.)

This is punched into the right-hand side of the frame,
behind the front wheel. The illustrations shows the VIN
no. location with the wheel removed, but it is still quite
visible with the wheel in place, with the steering at full
left lock.

Example: *YV3 R6 B5 13*

*VA 000029*
*YV3 R6 B5 1 3*
where YV3 denotes the manufacturer
*VA 000029* (YV3 = Volvo Bus Corporation, Sweden)
R6 chassis version (R6 = B7R)
B5 engine version (B5 = D7B 260)
(B2 = D7A 230; B3 = D7A 260;
B4 = D7B 230, C4 = D7A 285)
1 brake system
(1 = compressed-air brakes)
3 check digit
V model year (V = 1997)
(W = 1998, X = 1999, Y = 2000, etc.)
A assembly plant (A = Borås, Sweden)
(E = Volvo do Brazil)
000029 chassis number

1
Product data plate
If national regulations relating to GVW or axle load prescribe values
that are lower than the technical maximum values, the general agent or
importer must supplement the manufacturer’s data by inserting appro-
priate values in the left-hand column of the plate.
Component identification
D7 * 92987 *
2
The data plate is divided into a legislation part, outlined
separately on the plate, and three rectangular data fields
for chassis type, drive configuration and wheelbase (this
field is only completed for trucks, not buses).
On buses, the product data plate is attached to a location
next to the driver’s seat, and it contains the following
information.
If special national approval is required, the approval number is punched in
here by the relevant general agent or importer.
The VIN number, i.e. the same number as is stamped on the frame member,
is punched in here.
This field shows the max. technical GVW, in kg. This is the weight for which
the bus was designed.
Max. technical front axle load, in kg.
Max. technical rear axle load, in kg.
When relevant, the maximum technical axle load for the third axle is given
here, in kg.
Engine certificate plate
This plate specifies the exhaust emissions regulations
and characteristics.
1. ECE approval label
2. EU approval label (using the digital code for the relevant
EU country)
3. Engine part number
4. Engine version, manufacturer’s designation
5. Relevant emissions regulation and certificate number
6. Relevant smoke regulation and certificate number
7. Smoke rating under free acceleration
8. Relevant EU emissions regulations reference
Engine type designation, part number and
manufacturing number
These details are punched into the engine block above or
in front of the fuel injection pump.
D = Diesel, 7 = cylinder volume (litres), A = type A,
B = type B, 2XX = output horsepower
Clutch type and release bearing part number
These details are stamped on a plate attached to the
flywheel casing.
 Volvo Bus Co. Sweden Gearbox type designation, part number and
serial number
GEARBOX G8 EGS
All manual gearboxes and automatic transmission ver-
PART NO. SERIAL NO.
sions have a data plate attached to the top face of the
OIL CAPACITY 9 LITRES housing. (This illustration shows a typical plate on a
GEAR 1 2 3 4 5 6 7 8 Volvo G8 EGS gearbox.)
RATIOS 9,13 6,42 4,77 3,75 2,44 1,71 1,27 1,00

REVERSE 13,69

Electromagnetic retarder type designation

TELMA - Made in France and serial number
TYPE V No This information is punched into fields on a plate at-
CODE tached beneath the retarder.

Rear axle type designation, part number,

serial number (FABR NR) and ratio
This information is punched into fields on a plate at-
tached to the right hand side of the pinion housing.

3
 Service and maintenance

Engine
Oil grade ....................................................................... – Volvo Drain Specification VDS-2
– or VDS
– or API CE, CF, CF-4, CG-4
– or ACEA E1-96, E2-96, E3-96
For oil change intervals, refer to the D7 Engines
Service Manual, TP 16091.
Oil change volume including oil filter .......................... Approx. 20.7 litres

Viscosity as shown in the diagram below

-30 -20 -10 0 10 20 30 40 C The diagram assumes constant temperatures.

1. Refers to synthetic or VDS/VDS-2 oil.
-22 -4 14 32 50 68 86 104 F 2. VDS-2 oil.
SAE 10W/30

SAE 15W/40
SAE 10W/40 2)
SAE 5W/30 1)
SAE 5W/40 2)
SAE 30
SAE 40

Manual gearboxes
G8-EGS and G8-MGS
Oil change volume including oil filter .......................... Approx. 9 litres
Oil grade ....................................................................... – gearbox oil as per Volvo STD 1273,05 spec. 97305

– or engine oil to at least API CE, CF, CF-4, CG-4

or ACEA E1-96, E2-96, E3-96.

Viscosity as in the diagram below – or at low temperatures, use Volvo Synthetic Oil,
see note 3 on the viscosity diagram.

-30 -20 -10 0 10 20 30 40 C The diagram assumes constant temperatures.

1. Gearbox oil.
2. When driving in ambient temperatures above +30°C or
–25 C SAE 80W (1) 0 C
for prolonged periods at altitudes higher than 2000 m
–25 C SAE 80W/90 (1) above sea level, we recommend gearbox oil of SAE
(3)
(2) 85W/140 or SAE 140 viscosity.
3. At low temperatures, we recommend Volvo Synthetic
–25 C SAE 30 (4) 0 C Oil.
–25 C SAE 40 (4) +30 C 4. Engine oil. Note that multigrade oil is not permitted.

-22 -4 14 32 50 68 86 104 F

4
Manual gearbox ZF S6-85
Oil grade ....................................................................... – transmission oil API GL-4
– or ATF Dexron II D to Volvo STD 1273,35
spec. 97335
– or engine oil to at least API CE, CF, CF-4, CG-4
or ACEA E1-96, E2-96, E3-96.
– or at low temperatures, use Volvo Synthetic Oil,
see note 2 on the viscosity diagram.

Oil change amount ........................................................ 11.5 litres

Viscosity as in the diagram below

1. When driving in ambient temperatures above +30°C, or

for prolonged periods at altitudes higher than 2000 m
above sea level, we recommend gearbox oil of SAE
80W/90, 85W/90 or SAE 90 viscosity.
2. Volvo Synthetic Oil is recommended for ambient
temperatures below 25°C.
3. Engine oil. Note that multigrade oil is not permitted.

Mechanical clutch
Hydraulic control system, fluid grade .......................... SAE J 1703 (DOT 4)

ZF HP 500 automatic transmission

Oil grade ....................................................................... – ATF Dexron II D to Volvo STD 12735,5
spec. 97335
– or Volvo Synthetic oil to Volvo STD 1273,31 spec. 97331
Dry transmission filling volume ................................... approx. 20 litres
Oil change amount ........................................................ approx. 17 litres

Voith D863.3 automatic transmission

Oil grade ....................................................................... – ATF Dexron II D to Volvo STD 12735,5
spec. 97335
– or Volvo Synthetic oil to Volvo STD 1273,31
spec. 97331
Dry transmission filling volume ................................... approx. 25 litres
Oil change amount ........................................................ approx. 23 litres

5
Final drive EV80, EV85
Oil grade ....................................................................... API-GL-5 (MIL-L-2105D)
Viscosity as shown in the diagram below
Oil change volume ........................................................ Approx. 17.5 litres

-30 -20 -10 0 10 20 30 40 C

-22 -4 14 32 50 68 86 104 F
The diagram assumes constant temperatures.
SAE 80W/140

SAE 85W/140

SAE 140

Electromagnetic retarder (Telma Focal 191 or 200)

Lubricant ....................................................................... Supertelmaco 3 or Volvo equivalent

Power steering
Oil grade ....................................................................... ATF Dexron II D

Steering angle gear

Oil grade ....................................................................... ATF Dexron II D

Wheel hubs
Front wheels, lubricant ................................................. Engine oil SAE 30 (Final drive oil not permitted)
Oil volume, per hub ...................................................... Approx. 0.3 litres
Rear wheel bearings, lubricant ..................................... Lithium/lead wheel bearing grease with EP additive
and consistency as per NLGI-2

6
 Engine

EURO II
Type designation .......................................................... D7B230 D7B260 D7A285

Net power kW/hp at 36.7 r/s, 2200 rpm ....................... 169/230 191/260 210/285

Max.torque Nm/lb ft ..................................................... 825/608.5 1100/811 1200/885

at r/s, rpm ...................................................................... 26.7/1600 21.7/1300 23.3/1400

Net output factory set in accordance with ISO 1585.

These engines comply with the European EURO 2 emissions requirements.

US leg.
Type designation .......................................................... D7A230 D7A260 D7A280

Net power kW/hp at 36.7 r/s, 2200 rpm ....................... 171/230 194/260 208/280

Max.torque Nm/lb ft ..................................................... 895/660 1085/800 1152/850

at r/s, rpm ...................................................................... 25/1500 21.7/1300 21.7/1300

Gross output in accordance with ISO 2534 and SAE J 1995.

Smoke requirements in accordance with ECE/EEC regulations,US Federal Register and the Swedish norms.

All engines
No. of cylinders ............................................................ 6

Bore .............................................................................. 104.78 mm

Stroke ............................................................................ 130 mm

Displacement ................................................................ 6.7 dm3 (6.7 litres)

Compression ratio ......................................................... 18:1

Firing order ................................................................... 1-5-3-6-2-4

Direction of rotation (viewed from the front,

engine installed in bus) ............................................. Clockwise

Low idling speed .......................................................... 10±0.5 r/s (600±30 rpm)

High idling speed .......................................................... 40.8 to 42.5 r/s (2450 to 2550 rpm)

Dry weight, engine with flywheel and clutch housing

but without starter motor, approx. ............................ 700 kg

Max.overall dimensions, length/width/height (mm) .... 1230/681/1085

7
Engine block Gudgeon pins
Standard gudgeon pin diameter ...... 45 mm
Gudgeon pin fit to connecting rod
Cylinder head bush ............................................ 0.024 mm
Type ................................................ 1 per 3 cylinders
Length ............................................. 421 mm
Width .............................................. 233 mm

Cylinder head bolts

Valve mechanism
No./cylinder head ........................... 20
Thread dimension ........................... M11 Valves
Length ............................................. 150 mm Head diameters:
inlet ............................................. 43 mm
Cylinder block exhaust ........................................ 39 mm
Length ............................................. 859 mm Stem diameters:
Height, upper block surface inlet ............................................. 7.96 to 7.97 mm
to crankshaft centre (A), min. ..... 403 mm exhaust ........................................ 7.95 to 7.96 mm
Height, lower block face – Valve face angles:
crankshaft centre (B), min. ......... 90 mm inlet ............................................. 29.5°
exhaust ........................................ 44.5°
Contact face widths:
inlet ............................................. 2.3 mm
exhaust ........................................ 2.1 mm
Valve seat angles:
inlet ............................................. 30°
exhaust ........................................ 45°
Distance below cylinder head ......... 0 to 0.4 mm
Min. Min.

Cylinder liners
Type ................................................ Wet, detachable
Liner extent above top of block ...... 0.13 to 0.18 mm
Max. height difference between
cylinder liners 1, 2, 3 and 4, 5, 6 0.02 mm
Valve clearances, cold engine:
inlet ............................................. 0.40 mm
exhaust ........................................ 0.55 mm

Pistons The valves on D7A and D7B engines can be adjusted

Height above top of block .............. 0.55 mm
No. of ring grooves ......................... 3
Front markings ................................ Arrow forward
Piston rings
using the two groups method:
When piston no. 1 is at t.d.c. after compression, adjust
valve clearances 1, 2, 3, 6, 7 and 10.
When piston no. 6 is at t.d.c. after compression, adjust
valve clearances 4, 5, 8, 9, 11 and 12.

Compression rings
No. .................................................. 2
Groove clearances
upper compression ring .............. 0.4 mm
lower compression ring .............. 0.040 to 0.072 mm
Ring end gap ................................... 0.7 mm

Oil scraper ring

Number ........................................... 1
Groove clearance ............................ 0.050 to 0.082 mm

8
Valve seats
Outer diameter (dimension A), standard:
inlet ............................................. 46.08 mm
exhaust ........................................ 42.07 mm
Oversize:
inlet ............................................. 46.28 mm
exhaust ........................................ 42.27 mm
Height (dimension B):
inlet ............................................. 8.15 mm
exhaust ........................................ 8.65 mm
Valve seat position
Diameter (dimension C), standard (mm):
inlet ............................................. 46.000 to 46.025
exhaust ........................................ 42.000 to 42.025
Diameter (dimension C), oversize (mm):
inlet ............................................. 46.200 to 46.225
exhaust ........................................ 42.200 to 42.225
Depth (dimension D)
inlet ............................................. 9.95 to 10.05 mm
exhaust ........................................ 9.80 to 9.90 mm
Bottom radius of seat recess (dimension R):
inlet, max. ................................... 0.5 mm
exhaust, max. .............................. 0.5 mm
Valve guides
Inner diameters:
inlet ............................................. 8.000 to 8.015mm
exhaust ........................................ 8.000 to 8.015 mm
Heights above cylinder head spring plane:
inlet ............................................. 19.25 mm
exhaust ........................................ 19.25 mm
Stem to guide clearances:
inlet ............................................. 0.025 to 0.050 mm
exhaust ........................................ 0.038 to 0.064 mm
Valve springs, inlet and exhaust valves
Outer valve springs:
free length ....................................... 64.1 mm
with 270 to 310 N load ................... 48.6 mm
Inner valve springs:
free length ....................................... 60.1 mm
with 110 to 130 N load ................... 44.6 mm
Camshaft
Drive ............................................... Gear
No. of bearings ............................... 7
Minimum camshaft bearing journal diameters (mm):
front ................................................ 68.996 to 69.015
2nd .................................................. 66.621 to 66.640
3rd ................................................... 64.233 to 64.252
4th ................................................... 63.446 to 63.465
5th ................................................... 61.058 to 61.077
6th ................................................... 60.271 to 60.290
7th ................................................... 56.296 to 56.315
Maximum endfloat ......................... 0.05 to 0.13 mm
Maximum running clearance .......... 0.035 to 0.079 mm
Check camshaft setting with a cold engine and valve
clearance set to 0: With flywheel at 10° after t.d.c., the
inlet valve for cylinder no. 1 should be open by 4.5 mm.
Camshaft bearings
Camshaft bearing diameters (mm):
front ............................................ 69.050 to 69.075
2nd .............................................. 66.675 to 66.700
3rd ............................................... 64.287 to 64.312
4th ............................................... 63.500 to 63.525
5th ............................................... 61.112 to 61.137
6th ............................................... 60.325 to 60.350
7th ............................................... 56.350 to 56.375
Timing gears
Numbers of gear teeth
crankshaft gear (1) ............................. 30
idler gear (2) ...................................... 51
fuel injection pump drive gear (3) ..... 60
coolant pump drive gear (4) .............. 23
compressor drive gear (5) .................. 33
servo pump drive gear (6) ................. 19
camshaft drive gear (7) ...................... 60
idler gear for oil pump (8) ................. 48
oil pump drive gear (9) ...................... 27
9
Crank movement Main bearing shells
Thickness (D)
standard .................................... 2.931 mm
oversize 0.25 mm ..................... 3.058 mm
0.50 mm ..................... 3.185 mm
0.75 mm ..................... 3.312 mm
1.00 mm ..................... 3.439 mm
1.25 mm ..................... 3.566 mm

Crankshaft
Endfloat .......................................... 0.068 to 0.228 mm
Main bearing running clearance ..... 0.065 to 0.119 mm

The crankshaft is nitrocarburized. Note that a nitrocar-

burized crankshaft may only be ground as far as the
second undersize. If more grinding is required than this,
the crankshaft must be nitrocarburized again. Crankpins
Diameters (Ø) (mm):
standard ........................................... 69.837 to 69.850
Main bearing journals undersize 0.25 mm .......................... 69.583 to 69.596
Diameter (Ø) (mm): undersize 0.50 mm .......................... 69.329 to 69.342
standard .................................... 82.535 to 82.550 undersize 0.75 mm .......................... 69.075 to 69.088
undersize 0.25 mm ..................... 82.281 to 82.296 undersize 1.00 mm .......................... 68.821 to 68.834
0.50 mm ..................... 82.027 to 82.042 undersize 1.25 mm .......................... 68.567 to 68.580
0.75 mm ..................... 81.773 to 81.778 Width (A): ...................................... 43.900 to 44.000
1.00 mm ..................... 81.519 to 81.534 Fillet radius (R) .............................. 3.75 to 4.00 mm
1.25 mm ..................... 81.265 to 81.280 Maximum crankpin out-of-round. .. 0.08 mm
Maximum journal out-of-round. ..... 0.08 mm Maximum crankpin taper ............... 0.05 mm
Maximum journal taper .................. 0.05 mm

Widths (A) (mm): Big-end bearing shells

standard ........................................... 45.975 to 46.025 Thickness (C),
oversize 0.2 mm standard ...................................... 1.908 mm
(0.1 mm thrust bearing) .................. 46.175 to 46.225 oversize 0.25 mm ..................... 2.035 mm
oversize 0.4 mm 0.50 mm ..................... 2.162 mm
(0.2 mm thrust bearing) .................. 46.375 to 46.425 0.75 mm ..................... 2.289 mm
oversize 0.6 mm 1.00 mm ..................... 2.416 mm
(0.3 mm thrust bearing) .................. 46.575 to 46.625 1.25 mm ..................... 2.543 mm

Fillet radius (R) .............................. 3.75 to 4.00 mm

Connecting rods
Length between centres (E) ......... 250 mm
Thrust bearings Little-end bush internal dia. (G) .. 45.020 to 45.024 mm
Widths (B) Max. endfloat, crankshaft
standard .................................... 2.312 to 2.362 mm to connecting rod ..................... 0.250 mm
oversize 0.1 mm ..................... 2.412 to 2.462 mm Max. running clearance,
0.2 mm ..................... 2.512 to 2.562 mm connecting rod bearings ........... 0.066 to 0.112 mm
0.3 mm ..................... 2.612 to 2.662 mm

10
Lubrication system Fuel system
Oil pressures:
normal running ........................... 300 to 500 kPa Fuel injection pumps and regulators
idling, minimum pressure ........... 150 kPa
Engine Regulator Basic pump
type setting,
Lubricating oil pump b.t.d.c.
Type ................................................ Gear-driven
No. of teeth: D7A230 RQV250-1100 PA1072-K 7.5°±0.5°
drive gear .................................... 27
idler gear ..................................... 48 D7A260* RQV250-1100 PA1072-1K 6.0°±0.5°
Diameters:
idler gear bearing sleeve ............. 63.99 mm D7B230 RQV250-1100 PA1072-3K 8.5°±0.5°
idler gear bush ............................ 64.05 mm
End floats: D7B260* RQV250-1100 PA1072-4K 6.0°±0.5°
pump gear ................................... 0.07 to 0.18 mm
idler gear ..................................... 0.10 to 0.18 mm D7A285* RQV250-1100 PA1072-5K 6.0°±0.5°
Pump gear flank clearance .............. 0.15 to 0.30 mm
Clearance, pump gear to housing ... 1.0 to 1.5 mm D7A280* RQV250-1100 PA1072-2K 6.5°±0.5°

* fitted with injection timing device

Reduction valve
Marking .......................................... Brown Pump rotation,
viewed from coupling end .............. Clockwise
Fuel injection sequence .................. 1-5-3-6-2-4
Oil filter Feed pressure .................................. 100 to 400 kPa
Tightening torque
(with oiled sealing ring) ............. Hand-tight
Injectors and overflow valves
Engine type Injector type Overflow valve
Lubrication system valves
D7A230 DLLA-145 P 438 2 417 413 089
D7A260 DLLA-145 P 433 2 417 413 089
D7B230 DLLA-145 P 504 D 40 38 10 540
D7B260 DLLA-145 P 504 D 40 38 10 540
D7A285 DLLA-145 P 504 D 40 38 10 540
D7A280 DLLA-145 P 433 2 417 413 078

Numbering on complete injectors

and nozzle diameters
Engine type Numbering Nozzle diameter

D7A230 0 432 191 666 6 x 0.198 mm

D7A260 0 432 191 669 6 x 0.202 mm
D7B230 0 432 191 634 6 x 0.208 mm
D7B260 0 432 191 634 6 x 0.208 mm
D7A285 0 432 191 634 6 x 0.208 mm
A. Overflow valve D7A280 0 432 191 669 6 x 0.202 mm
Free spring length ........................... 68.8 mm
Length with 140±1 Nm load........... 40.0 mm Injector retaining collars
(all engines) .................................... KBEL 98P102
B. Piston cooling valve Opening pressure
Markings ......................................... White (all injector types) ........................... 250 +8/–0 MPa
Setting pressure
C. Reducing valve (all injector types) ........................... 260 +8/–0 MPa
Markings ......................................... Blue

11
Injection timing device Cooling system
Bearing diameter (mm) ................... 67.050 to 67.075
Type ................................................ Overpressure
Engine Engine speed Maximum Pressure valve opens at ................... 50 kPa
type when timing timing angle
change begins change, at
engine speed Coolant
Type ................................................ C
D7A260 1800 rpm (30 r/s) 5.0° b.t.d.c.
Consists of ...................................... Antifreeze with
at 2200 rpm (36.7 r/s)
corrosion-inhibit-
D7B260 1380 rpm (23.0 r/s) 6.0° b.t.d.c.
ing additives
at 1620 rpm (27.0 r/s)
Colour ............................................. Blue-green
D7A285 1380 rpm (23.0 r/s) 6.0° b.t.d.c.
at 1620 rpm (27.0 r/s)
D7A280 1800 rpm (30 r/s) 5.0° b.t.d.c.
at 2200 rpm (36.7 r/s) Coolant pump
Type ................................................ Gear-driven
centrifugal pump
Fuel filter
Quantity .......................................... 1 Thermostat
Type ................................................ Piston thermostat
Opening temperature ...................... 82±2°C
Fuel tanks Fully open at ................................... 92±2°C
Transport only ................................ 50 litres
Transport mounted .......................... 400 litres
Ahead of rear axle, right-hand side 300 litres
Mounted in wheelbase .................... 2 x 150 litres

Inlet and exhaust system Wear tolerances

Turbocharger Cylinder liners

Full load boost pressures at 2000 rpm The cylinder liners (together with their pistons and
D7A230, D7B230 engines .............. 160 to 180 kPa piston rings) must be replaced if their internal diameter
D7B260, D7A285, D7A260, has increased by 0.35 to 0.40 mm, or if the oil consump-
D7A280 engines ............................. 150 to 170 kPa tion is abnormally high.
Turbocharger wastegate opens
by 1 mm at a pressure of ............ 185 kPa
Crankshaft
NOTE: The specified values must not be exceeded, as Max. permitted out-of-round on
this can damage the engine. main bearing journals and
crankpins .................................... 0.08 mm
Wastegate Max. permitted taper on main
Fitted to turbochargers on D7A260, D7B260, D7A285 bearing journals and crankpins ... 0.05 mm
and D7A280 engines. Maximum crankshaft endfloat ........ 0.40 mm
Opening pressure for testing ........... 185±2 kPa Max. permitted warp on centre
Setting value for control travel main bearing journal ................... 0.15 mm
(at 185 kPa) ................................ 0.5 to 1.04 mm
Reference value for control travel
(at 185 kPa) ................................ 0.33 to 1.27 mm Connecting rods
Straightness, max. permitted
Starter heater element deviation per 100 mm
Output rating ................................... 2700 W measured length .......................... 0.01 mm
Twist, max. deviation per 100 mm
Air intake pressure drop indicator measured length .......................... 0.10 mm
Red indication at ............................. 6.5±0.7 kPa

12
Valves Tightening torques
Max. permitted valve stem wear .... 0.02 mm
Max. permitted clearances Cylinder head (tightened in 4 stages, in the order shown
between stem and guide: in the diagram below)
inlet ............................................. 0.33 mm first stage .................................... 30 Nm
exhaust ........................................ 0.38 mm second stage ................................ 90 Nm
Minimum contact face width third stage ................................... 90 Nm
on valve head disc: fourth and final stage .................. 60° further
inlet ............................................. 2.0 mm
exhaust ........................................ 1.0 mm
The valve seats may be reground until the distance from
the inlet (A) or exhaust (B) valve face is not more than
0.04 mm. If the distance exceeds this amount, the valve
seat or seats must be changed.

Main bearing cap nuts .................... 150±10 Nm

Big-end bearing cap nuts ................ 190±10 Nm
Camshaft thrust bearing
securing screws ........................... 55±Nm
Timing gear casing and noise
damping plate securing screws ... 33±4 Nm
Camshaft drive gearwheel
securing screws ........................... 60±7 Nm
Fuel injection pump drive gearwheel
securing screws ........................... 33±4 Nm
Idler gearwheel bearing
Camshaft securing screw ............................ 90±9 Nm
Rocker shaft bearing bracket
Max. permitted out-of-round
securing screws ........................... 50±7 Nm
(with new bearings) ........................ 0.05 mm
Oil sump securing screws ............... 24±3 Nm
Max. permitted bearing wear .......... 0.05 mm
Oil sump drain plug ........................ 80±9 Nm
Minimum tappet heights:
Flywheel securing screws ............... 190±10 Nm
inlet ............................................. 8.33 mm
Flywheel casing securing screws .... 140±14 Nm
exhaust ........................................ 8.33 mm
Crankshaft belt pulley
securing screws ........................... 90±9 Nm
Crankshaft centre bolt ..................... 260±25 Nm
Flywheel, in place Piston cooling nozzle nut ................ 33±4 Nm
Max. permitted axial throw Oil pump front plate to main
(manual gearboxes), at 150 mm bearing cap securing screws ....... 65±7 Nm
measurement radius .................... 0.15 mm Oil pump idler gearwheel
securing screws ........................... 33±4 Nm
Oil delivery pipe nut
Flywheel housing, in place with compression ring, new ........ turn nut 180°
Max. permitted axial throw Oil delivery pipe nut
of flywheel housing contact with compression ring, re-used .. turn nut 60°
surface to clutch housing ............ 0.15 mm Fuel injection pump bracket,
Max. permitted radial throw screws securing bracket to pump 33±3 Nm
of internal Fuel injection pump bracket,
flywheel housing screws securing bracket
edge to clutch housing ................ 0.25 mm to engine block ........................... 25±6 Nm

13
Fuel injector securing yoke nuts ..... 50±5 Nm Tightening torque table for nuts marked 8:8
Fuel injection pump coupling
M12 clamp screw ........................... 114±10 Nm Note: Any bolts or screws that are not listed above, but
Exhaust manifold securing nuts carry the standard 8:8 marking should be tightened in
first tighten to ............................. 10±2 Nm accordance with the following table:
then further to ............................. 60±5
Turbocharger securing nuts Thread Diameter Tightening torque
first tighten to ............................. 10±2 Nm
then further to ............................. 60±5 M5 5 mm 6±1 Nm
Turbocharger compressor wheel M6 6 mm 10±1.5 Nm
lock nut M7 7 mm 17±3 Nm
(NOTE: left-hand thread) ........... 17 Nm M8 8 mm 24±4 Nm
Turbocharger bearing housing M10 10 mm 48±8 Nm
securing screws to turbine M12 12 mm 85±15 Nm
housing ....................................... 14 Nm M14 14 mm 140±25 Nm
Exhaust gas pressure regulator
piston nut .................................... 10.5±0.5 Nm

14
 Electrical system and instruments
System voltage .............................................................. 24V

Batteries
Number of batteries, voltage, individual capacity ........ 2 x 12V, 170 Ah
Ground (earth) connection ............................................ Negative terminal
Specific gravity of electrolyte:
in fully charged battery ............................................. 1.28
when battery needs to be recharged .......................... 1.24
Recommended charging voltage .................................. Approx. 28V
Charging time from full discharge ............................... Approx. 16 hours

Alternator 80A
Number/Nominal voltage ............................................. 1 or 2/28V
Manufacturer/Designation ............................................ Bosch N1-28V 10/80A
Rotation ........................................................................ Reversible
Drive ............................................................................. Belt
Weight, per alternator ................................................... 6.8 kg
Maximum output power, per alternator ........................ 2 240 W
Pair connection ............................................................. Parallel
Cut-in speed .................................................................. 1 350 rpm
Maximum load speed ................................................... 6 000 rpm
Maximum permitted speed ........................................... 11 000 rpm
Charging regulator ........................................................ Integrated, transistorised
Maximum ambient temperature ................................... 80°C

Starter motor
Manufacturer/Designation ............................................ Bosch JF (R) 24V, 4.0 kW
Mode of operation ........................................................ Sliding pinion
Polarity ......................................................................... Negative ground
Power rating .................................................................. 4.0 kW
Number of brushes ....................................................... 4
Lubricant ....................................................................... Volvo Grease (Equivalent to Bosch FT2V3)
Gear ratio, starter motor-engine.................................... 15.6:1 (9 teeth on the starter pinion)

Starter motor electrical testing values

Free running starter motor:
Speed ............................................................................ 116.7 r/s (7 000 rpm)
Current .......................................................................... 50 A
Voltage ......................................................................... 23.5V

Stalled starter motor

Voltage ......................................................................... 13.5 V
Current .......................................................................... 900 to 1050 A

Starter solenoid
Minimum actuating voltage .......................................... 18V

Tachograph calibration values

Refer to the current Tachograph and Speedometer Service Bulletin 3(38) for details of the calibration methods and
values applicable to the instruments installed in B7R buses.

15
 Power transmission, rear axle
Clutch
For Volvo G8 MGS, G8 EGS or ZF S6-85 manual gearbox
Type .............................................................................. Pull-type single dry disc clutch
Designation ................................................................... KFD 116B
Plate outer diameter ...................................................... 400 mm (nominally 16")
thickness, installed .................................................... 10 mm
Max.permitted wear (per lining) ................................... 1.5 mm
Total frictional area ...................................................... 1753 cm2

Clutch spring
Diaphragm spring activation force ............................... 18 500 to 21 500 N

Flywheel
Distance friction surface – attachment plate surface .... 44.4±0.1 mm
Max. permitted grinding of friction surface (the
distance between friction surface and attachment
plate is retained) ....................................................... 0.5 mm
Distance, friction surface – flywheel ............................ 50.1±0.5 mm
Max. permitted conicity ................................................ 0.3 mm

Clutch pedal, servo system

Clutch pedal play .......................................................... 3.5 to 6.0 mm
Master cylinder travel ................................................... 30 mm
play, master cylinder piston to pushrod .................... 0.5 mm
Basic setting, operating cylinder piston stroke,
from operating cylinder wall to lock nut .................. 45.0±1.5 mm
Release bearing travel ................................................... 12 to 14 mm
Servo cylinder travel ..................................................... 30 to 32 mm
Inductive sensor pedal movement (G8 EGS) ............... 130±10 mm
Inductive sensor to indicator plate setting (G8 EGS) ... 3±0.5 mm

Manual gearbox, ZF S6-85

Type .............................................................................. Mechanical 6-speed with full synchromesh
Weight .......................................................................... approx. 170 kg
Gear ratios:
1st ............................................................................ 7.72:1
2nd ........................................................................... 4.42:1
3rd ............................................................................ 2.85:1
4th ............................................................................ 1.91:1
5th ............................................................................ 1.30:1
6th ............................................................................ 1.00:1
Reverse .................................................................... 7.09:1

Tightening torques (Nm)

Companion screw, output shaft .................................... 60
Securing screws:
front, rear, gearbox and countershaft covers ............ 45
Reverse inhibit mechanism cover ................................. 60
Selector fork pins .......................................................... 250
Oil drain, fill and level checking plugs ........................ 50
Clutch housing securing screws ................................... 250 to 300

16
Manual gearbox, Volvo G8 EGS/G8 MGS
Type G8 EGS (Easy Gear Shift)................................... Mechanical 8-speed with full synchromesh and
electro-pneumatic gearchange system.

Type G8 MGS (Manual Gear Shift) ............................. Mechanical 8-speed with full synchromesh.
Electro-pneumatic high/low range switching.

Weight, gearbox without retarder ................................. approx. 260 kg

gearbox with retarder ................................................ approx. 360 kg

Gear ratios:
1st ............................................................................ 9.13:1
2nd ........................................................................... 6.42:1
3rd ............................................................................ 4.77:1
4th ............................................................................ 3.75:1
5th ............................................................................ 2.44:1
6th ............................................................................ 1.71:1
7th ............................................................................ 1.27:1
8th ............................................................................ 1.00:1
Reverse .................................................................... 13.69:1
Axial clearance, gears
1st, mainshaft ........................................................... 0.4 to 0.7 mm
2nd, mainshaft ......................................................... 0.3 to 0.5 mm
3rd, mainshaft .......................................................... 0.3 to 0.5 mm
reverse, mainshaft .................................................... 0.3 to 0.5 mm
reverse, reverse shaft ............................................... 0.25 to 0.75 mm
Planetary gear, axial clearance ..................................... 0.6 to 1.3 mm
Bearing pre-load, main and intermediate shafts ........... 0.1±0.05 mm
Circlips, clearance ........................................................ 0 to 0.10 mm
Synchromesh:
wear limit, synchromesh ring/clutch ring,
distance between rings ............................................. min. 0.7* mm
interlock forces, basic gearbox ................................ 370 to 570 N
interlock forces, planetary gear ............................... 450 to 650 N

Control housing, gear selector adjusted to

mid-position within ................................................. ±0.1 mm (applies to forward ratios)
reverse gear adjusted to ........................................... 1.3±0.4 mm in front of rear stop position

* For gearboxes run less than 200,000 km, we recommend

replacement of worn parts if the distance is less than 1.4 mm.

Oil pump
Capacity at 1000 r/min and oil temp. 70°C .................. approx. 9 litres/minute
Oil pressure at 1000 r/min and oil temperature:
40°C ......................................................................... 0.7 to 1.3 kp/cm2
60°C ......................................................................... 0.4 to 0.8 kp/cm2
80°C ......................................................................... 0.3 to 0.7 kp/cm2
Opening pressure, reduction valve ............................... 5±1 kp/cm2
Play (radial) pump ring – rotor ..................................... max. 0.20 mm
Play (axial) rotor – pump housing ................................ max. 0.20 mm

17
 Volvo EGS (Easy Gear Shift) system
Type ................................................ Electro-pneumatic
Control unit fuse ............................. 5A SAE type

Colour coding of 35-way control unit

connectors
K1 ................................................... Gray
K2 ................................................... Black

Solenoid valve, blocking cylinder for gear

lever
Current consumption ...................... 0.2 A
Output ............................................. 5 W
Minimum hold-in voltage. .............. 10 V
Resistance ....................................... 110 Ω
Operating voltage range ................. 21 to 30 V

Solenoid valve, gearbox

Current consumption ...................... 0.41 A
Output ............................................. 10 W
Hold-in voltage, min. ...................... 10 V
Resistance ....................................... 60 Ω
Operating voltage range ................. 21 to 30V

Tightening torques
Thread dimension Nm kpm
Screw, clutch housing .................................................. M16 200±25 20±2.5
range gearbox – base gearbox .......................... M12 75±10 7.5±1
cover; input, main and idler shafts ................... M10 40±5 4.0±0.5
cover for PTO (without retarder) ..................... M12 25±5 2.5±0.5
bracket, clutch servo ......................................... M12 75±10 7.5±1
sensor housing on control housing (hexagonal) M8 20±3 2.0±0.3
Contacts and speed sensors .......................................... M18 x 1.5 40±5 4.0±0.5
Screw, control housing (hexagonal) ............................. M12 50±5 5.0±0.5
end wall, control housing ................................. M8 20±3 2.0±0.3
cover, control housing ...................................... M6 5 to 8 0.5 to 0.8
piston rod, control housing ............................... M10 40±5 4.0±0.5
Lock screw, gear selector (hexagonal) ......................... 35±5* 3.5±0.5*
Lock screw for shift fork, 3rd–4th, base gearbox) ....... M16 75±7* 7.5±0.7*
Screw, attachment for fork retainer, base gearbox ....... M10 40±5 4.5±0.5
Lock screw for shift fork, range (without retarder) ...... M16 75±7* 7.5±0.7*
Screw, range cylinder (without retarder) ...................... M10 40±5 4.0±0.5
piston, range cylinder ....................................... M10 40±5 4.0±0.5
pivot pins, shift fork (with retarder) ................. M8 20±3 2.0±0.3
cover, range cylinder (with retarder) ................ M10 40±5 4.0±0.5
Oil distributor pipe, attachment to mainshaft ............... M32 x 1.5 250±30 25±3
Screw, oil pump and collection pipe ............................ M8 20±3 2.0±0.3
filter shield, oil filter ........................................ M10 40±5 4.0±0.5
Magnetic plug, oil drainage/filling ............................... M24 x 1.5 70±20 7.0±2
Plug, oil pressure control .............................................. M16 x 1.5 30±5 3.0±0.5
Lock nut, flange ............................................................ 450±50 45±5

* Locked by tapping a punch.

18
Automatic transmission, ZF 4/5 HP 500/590
Type .............................................................................. Fully automatic 4 speed transmission
with torque converter and built-in retarder
Gear selector ................................................................. Push-button type
Mechanical gear ratios:
1st ............................................................................ 3.43:1
2nd ........................................................................... 2.01:1
3rd ............................................................................ 1.42:1
4th ............................................................................ 1.00:1
Reverse .................................................................... 4.84:1
Torque converter hydraulic ratio .................................. 2.16:1

Sizes and distances

Torque converter, dimension of gearbox housing to
torque converter (attachment surface) ...................... 81.25±0.5 mm (without starter ring)
Gap between inductive sensor and gear teeth tips ........ 0.6 to 0.8 mm

Oil pressure
Values checked at normal transmission
operating temperature, 60 to 80°C: .............................. MPa bar Engine speed, rpm
1. Main pressure, N position ....................................... 1.8±0.2 18±2 approx. 700 to 2 000
D position with lock-up engaged............................. 1.0±0.2 10±2 over 2 000
2. Modulator pressure .................................................. 0.60 to 0.65 6.0 to 6.5
reduces to adjusted pressure for the respective gear at
the instant of change (less than 1 second approx.);
approx. 0.5 bar in N or D while idling.

Tightening torques
Nm
Drain plug, oil sump ..................................................... 50 to 60
oil cooler .................................................................. 21 to 25
Oil filter cover and oilsump securing screws ............... 25
Inductive sensor ............................................................ max. 50
Inductive sensor plug .................................................... 80 to 100
Engine to transmission securing screws:
large (M12) .............................................................. 70 to 90
slotted screws on starter ring (M8) .......................... 20 to 26
Flywheel cover mounting nuts ..................................... 67±6
Torque converter centre plug ........................................ 190 to 210

19
Automatic transmission, Voith D863.3
Type .............................................................................. Fully automatic three-stage transmission with torque
converter on first stage, also acting as a retarder.
Gear selector ................................................................. Push-button type
Gear ratios:
1st (hydraulic).......................................................... 5.37:1
2nd ........................................................................... 1.36:1
3rd ............................................................................ 1.00:1
Reverse .................................................................... 4.80:1
Torque converter pressures:
working pressure at 1 500 rpm, directly
after changing to 2nd gear ....................................... 0.8 to 0.85 MPa
D selected, brakes applied, engine speed
500 to 550 rpm, oil temperature 90°C ..................... 0.3 MPa minimum

Tightening torques
Nm kpm
Screws, driver, output shaft .......................................... 68 6.8
Flywheel housing securing nuts ................................... 60±5 6.0±0.5
Companion plate screws ............................................... 60±5 6.0±0.5
Torque converter drain plug ......................................... 50 5.0
Oil sump drain plug ...................................................... 50 5.0
Filter cover .................................................................... 50 5.0

Propeller shaft
Fully compressed overall lengths:
for Volvo G8 EGS/MGS ......................................... 545 mm
for ZF S6-85 gearbox .............................................. 675 mm
for ZF transmission ................................................. 541 mm
for Voith transmission ............................................. 531 mm

Maximum angular movement on yokes:

Volvo G8 and ZF S6-85 manual gearboxes ............ 22°
ZF and Voith automatic transmissions .................... 27°

Inner yoke phasing:

Volvo G8 EGS/MGS/ZF S6-85 gearboxes ............. 0°±1°
ZF transmission ....................................................... 20.8°±2°
Voith transmission ................................................... 19.9°±2°

Flange, max. permitted axial play ................................ None

Tightening torque, flange bolts

Volvo G8 and ZF S6-85 manual gearboxes ............ 70±5 Nm
ZF and Voith automatic transmissions .................... 190±13 Nm

Universal joints, recommended lubricant ..................... Shell Retinax LX, alternatively equivalent VTC grease

20
Single reduction final drive EV 80 B
Type .............................................................................. Hypoid gears
Reduction ratios ............................................................ 3.78:11, 4.30:1, 4.87:1, 5.43:1
Adjustment of pinion bearing:
Required traction 15 tonnes on front bearing
new and run-in bearings .......................................... 45 to 75 N (4.5 to 7.5 kgf)
Backlash ....................................................................... 0.30 to 0.40 mm
Adjustment of thrust bolt .............................................. Backed off one turn from contact with crown wheel
1
Not in combination with Voith D863 automatic transmission.

Tightening torques
Nm See note
Differential housing bolts ............................................. 100 1
Crown wheel bolts ........................................................ 150 1
Cap bolts ....................................................................... 430 2
Companion flange nuts, pinion, minimum. .................. 1200 3
Pinion bearing sleeve .................................................... 135 1
Thrust bolt lock nut ...................................................... 100
Bolt for locking lug ...................................................... 20
Right adjustment nut tightened to zero play and then .. 2 to 3 flats
1
The bolts are tightened diagonally to the prescribed torque and then on to the next split pin hole.
2
After tightening, the screws are locked in pairs.
3
After tightening to the prescribed torque, if necessary tighten further so that the most suitable lock tab fits the nearest position.

Single reduction final drive EV 85 B

Type .............................................................................. Hypoid gears
Reduction ratios ............................................................ 3.562, 3.78:11, 4.25:1, 4.87:1, 5.43:1
Adjustment of pinion bearing:
Required traction 15 tonnes on front bearing
new and run-in bearings .......................................... 60 to 80 N
Gear flank clearance ..................................................... 0.30 to 0.40 mm
Adjustment of thrust bolt .............................................. Backed off one turn from contact with crown wheel
1
Not in combination with Voith D863 automatic transmission.
2
Only in combination with manual gearboxes.

Tightening torques
Nm See note
Differential housing bolts ............................................. 210 1
Crown wheel bolts ........................................................ 210 1
Cap bolts ....................................................................... 350 2
Companion flange nuts, pinion, minimum. .................. 1000 3
Pinion bearing sleeve .................................................... 140 1
Thrust bolt lock nut ...................................................... 100
Bolt for locking lug ...................................................... 15
Right adjustment nut tightened to zero play and then .. 3 to 4 flats
1
The bolts are tightened diagonally to the prescribed torque and then on to the next split pin hole.
2
After tightening, the screws are locked in pairs.
3
After tightening to the prescribed torque, if necessary tighten further so that the most suitable lock tab fits the nearest position.

21
 Brakes
Wheel brakes
Type .............................................................................. Compressed air-operated
Design ........................................................................... Simplex type S-cam
Diameter (front and rear wheels) .................................. 393.7 mm
Operating pressure ........................................................ 7.1 to 8.3 kgf/cm2

Brake drum
Maximum permitted wear (including turning) ............. 3 mm on the diameter
Maximum permitted out-of-round ................................ 0.25 mm
after machining ......................................................... 0.1 mm on the diameter

Brake linings
Width ............................................................................ 203 mm (front), 254 mm (rear)
Size:
front wheels (8") ....................................................... 200 x 19 x 381 mm
rear wheels (10")....................................................... 250 x 19 x 381 mm
Oversize, thickness ....................................................... 20.5 mm
Clearance, lining to drum ............................................. 0.30 to 0.35 mm
Effective brake friction area on each axle
front axle ................................................................... 3055 cm2
rear axle .................................................................... 3810 cm2
Total brake friction area ............................................... 6865 cm2

Compressor
Designation ................................................................... *Knorr KOMPR 213 Knorr LP 48
Type .............................................................................. Piston, water cooled head Piston, water cooled head
No. of cylinders ............................................................ 1 2
Air capacity at 700 kPa counterpressure and
compressor speed of 2000 r/min ............................... 275 dm3/min (275 l/min) –
Air capacity at 800 kPa counterpressure and
compressor speed of 2000 r/min ............................... – 530 dm3/min (530 l/min)
Max.pressure ................................................................ 1200 kPa (12 bar) 1200 kPa (12 bar)
Max. operational speed, compressor ............................ 3000 rpm 2400 rpm
Cylinder bore, standard ................................................ 88.0 mm 75.0 mm
Stroke ............................................................................ 35 mm 50 mm
Displacement ................................................................ 213 cm3 440 cm3
* The KOMPR 213 lower capacity compressor is only permitted in buses with spring suspension. Full air suspension buses must have the LP 48.

Check measurements, wear etc. (for both KOMPR 213 and LP 48)
Cylinder bore, maximum wear ..................................... 0.16 mm
Piston rings, max.permitted play in groove .................. 0.05 mm
Piston ring gap, minimum, in cylinder ......................... 0.50 mm
Crankshaft bearing, max. permitted wear ..................... 0.13 mm
Big-end bearing, max. permitted wear ......................... 0.20 mm
Crankshaft axial play, max. permitted wear ................. 0.60 mm

Tightening torques, KOMP 213 compressor

Drive gear wheel ........................................................... 200 to 250 Nm
Cylinder-block bolts ..................................................... 22 to 24 Nm
Cylinder head bolts ....................................................... 30 to 33 Nm
Front cover .................................................................... 23 to 25 Nm
End cover ...................................................................... 22 to 24 Nm
Disc valve screws ......................................................... 11.4 to 12.6 Nm

22
Tightening torques, LP 48 compressor
Drive gear wheel ........................................................... 200 to 250 Nm
Cylinder-block bolts ..................................................... 22 to 24 Nm
Cylinder head bolts, stage 1 .......................................... 3 Nm
Cylinder head bolts, stage 2 .......................................... 30 to 33 Nm
Valve plate, long screws ............................................... 12 to 15 Nm
Valve plate, short screws .............................................. 11.4 to 12.6 Nm
Connecting rod bolts, without bearing shells ............... 13 to 16 Nm
Connecting rod bolts, with bearing shells .................... 33 to 38 Nm
Bottom cover ................................................................ 5.5 to 6.5 Nm
Rear cover ..................................................................... 22 to 24 Nm

Air drier
Type .............................................................................. Haldex single-tower type with replaceable element
Pressure regulator ......................................................... Built-in
Maximum cut-out pressure ........................................... 8.7 bar
Minimum cut-in pressure ............................................. 7.3 bar

Safety valve
Opening pressure .......................................................... 0.93±0.035 MPa

Tightening torques for cap nuts at brake pipe connections

Steel pipes ..................................................................... Nm kpm
6 mm pipe ................................................................ 20 2
8 mm pipe ................................................................ 25 2.5
1/4" pipe .................................................................. 20 2
3/8" pipe .................................................................. 25 2.5
5/8" pipe .................................................................. 40 4

Plastic pipes
1/4" pipe .................................................................. 15 1.5
3/8" pipe .................................................................. 20 2
1/2" pipe .................................................................. 30 3
5/8" pipe .................................................................. 40 4

Compressed air tanks

Two-axle bus
Primary (wet) tank ........................................................ 30 dm3 (litres)
Regeneration tank ......................................................... 6 dm3 (litres)
Front brake circuit tank ................................................ 30 dm3 (litres)
Rear brake circuit tank .................................................. 30 dm3 (litres)

Drain valves
Type .............................................................................. Manual

23
Four-circuit protection valve
Designation ................................................................... Knorr-Bremse AE 4427
Closing pressure, footbrake circuit ............................... min. 580 kPa
parking brake and other air equipment .................... min. 470 kPa
Opening pressure, footbrake circuit.............................. 670–700 kPa
parking brake and other air equipment .................... 540–570 kPa

Footbrake valve (2-circuit)

Max. permitted difference in brake pressure between
the two circuits in the entire pressure range ............ 20 kPa

Low-pressure indicator
Activation pressure, parking brake ............................... 510–570 kPa
footbrake circuit ...................................................... 460–520 kPa

Brake light switch

Closing pressure ........................................................... 10–50 kPa

Relay valve
Type .............................................................................. With connector for silencer

Hand control, parking brake

Type .............................................................................. Knorr HB 1143

Blocking valve
Valve closes when pressure falls below ....................... 340–400 kPa
Control button remains pressed in if the pressure
in the tank exceeds the closing pressure.

Brake cylinders
All wheels (spring suspension)
Size ............................................................................... 30# (= diaphragm area in sq.in.)
Max. permitted stroke ................................................... 51 mm
Rear wheels (air suspension)
Type .............................................................................. 2424

Test nipple
Connection thread ......................................................... M16 x 1.5 mm

Lubricant
Brake cam, automatic slack adjuster
(when dismantling) .................................................. Grease Li/EP NLGI no. 2, available in 80 g or 400 g

24
Electromagnetic brake (retarder option for manual gearbox buses)
Buses with ZF S6-85 gearbox
Manufacturer/designation ............................................. Telma 191
Braking torque, max. .................................................... 1910 Nm
No. of coils/Voltage ...................................................... 8/24V
Air gap, rotor-pole shoe ................................................ 1.1–1.2 mm (mean value measured at each shoe)
Current consumption per braking stage at approx. 24 V 26.5 A
Current consumption, full engagement ........................ 106 A
Axial play, rotor bearing ............................................... 0.05–0.08 mm
Weight without transmission ........................................ 203 kg

Buses with Volvo G8 MGS gearbox

Manufacturer/designation ............................................. Telma Focal 200
Braking torque, max. .................................................... 2200 Nm
No. of coils/Voltage ...................................................... 8/24V
Air gap, rotor-pole shoe ................................................ 1.8±0.15 mm (mean value measured at each shoe)
Current consumption per braking stage at approx. 24 V 33 A
Current consumption, full engagement ........................ 132 A
Axial play, rotor bearing ............................................... 0.05–0.08 mm
Weight without transmission ........................................ 207 kg

Tightening torques
Connecting flange nuts ................................................. 450 Nm

Front suspension and steering

Wheel angles
Caster angle .................................................................. 3.5°±0.25°
Adjustment washers for caster (air-suspension version) 2 mm, 4 mm
Angle change, adjustment washer ................................ 2 mm = 0.6°, 4 mm = 1.2°
Camber ......................................................................... 0.75°±0.25°
Inward inclination of king-pin (KPI) ............................ 5.75°±0.25°
Toe-in ........................................................................... 0–3 mm
Curve angles (max. wheel lock), front axle inner wheel 45°±1°
outer wheel ............................................................... 32°

Front axle
Type .............................................................................. Rigid
King-pin diameter (in bushing) .................................... 48 mm
Shims for king-pin bearing, thickness .......................... 0.25 mm, 0.35 mm, 0.40 mm
Axial clearance for king-pin bearings .......................... 0.05–0.10 mm

Power steering
Type .............................................................................. Recirculating ball and nut with integral servo unit
Max. output torque at 150 kgf/cm2 pressure ................. 4 864 Nm
Steering wheel diameter ............................................... 500 mm
No. of steering wheel turns lock to lock ....................... approx. 4.5

25
Servo pump
Manufacturer/designation ............................................. ZF
Max. pump pressure ..................................................... 13 MPa
Min. capacity at 80°C,
8.3 r/s (500 rpm) pump speed, 5 MPa (50 kgf/cm2) ..... 5.6 litres/min
16.7 r/s (1000 rpm) pump speed, 5 MPa (50 kgf/cm2) . 13.8 litres/min
Max. capacity ............................................................... 16 litres/min
Reduction ratio, engine – pump .................................... 1:1.47

Tightening torques
Nm
Steering wheel nut ........................................................ 70–80 Nm
Pitman arm screw ......................................................... 425–525 Nm
Nut for ball stud, link rod ............................................. 160–210 Nm

Frame, suspension, wheels

Frame
Main members .............................................................. 2 steel U-section longitudinal members
Overall length including body ...................................... 12 000 mm
Frame width .................................................................. 862 mm
No. of cross-members ................................................... 8
Constant web height of frame ....................................... 230 mm
Flange width ................................................................. 77 mm
Material thickness ......................................................... 6 mm

Parabolic springs variant

Front springs
Length ........................................................................... 1600 mm
Width ............................................................................ 100 mm
Number of leaves .......................................................... 3
Test value (removed from bus)
force required to straighten springs .......................... 28 450 N±200 N

Rear springs
Length ........................................................................... 1600 mm
Width ............................................................................ 100 mm
Number of leaves .......................................................... 4
Test value (removed from bus)
force required to straighten springs .......................... 41 700 N±200 N

26
Air suspension variant

Suspension system
No. of air bellows ......................................................... 2 at front, 4 at rear
Working pressure at full load
front .......................................................................... 760 kPa
rear ............................................................................ 530 kPa
Max. air pressure for spring system.............................. 1180 kPa
Min. air pressure (working pressure) ............................ 900 kPa
Low-pressure sensor on compressed-air
container, suspension ................................................ 750 kPa

Air bellows height

Front axle ...................................................................... 279±3 mm1
Rear axle ....................................................................... 249±3 mm1
1
Distance measured between bellows piston lower edge and lower edge of upper attachment plate.

Shock absorbers
Type .............................................................................. Double-acting hydraulic telescopic
Number ......................................................................... 4 at front, 2 at rear

Rear suspension circuit pressure limiting valve

Operating pressure ........................................................ 1.3 MPa
Limit pressure ............................................................... 750 kPa

Manual height control

Height increase ............................................................. ±80 mm
System pressure at max. load ....................................... 1050 kPa

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Wheel rim dimensions
Steel disc 10-bolt wheels
for 11.00R20" tyres .................................................. 8.5 x 20.0"
for 12R22.5" or 295/80R22.5" tyres ......................... 8.25 x 22.5"

Tightening torques
Lock nuts, front wheel hubs ......................................... 450* Nm
Hub caps, front wheel nuts ........................................... 250 Nm
M12 attaching screw, reaction rod brackets
and reaction rods ........................................................... 85 Nm
Shock absorber attachment, front axle
upper ......................................................................... 200 Nm
lower ......................................................................... 115 Nm
Shock absorber attachment, rear axle
upper and lower ........................................................ 200 Nm
* Slacken 60° after tightening.

Tyres
The tyres indicated below are the most common,
but other sizes are also available.
Dimension
Tyres with tubes ........................................................... 11.00R20"
Tubeless tyres ............................................................... 12R22.5", 295/80R22.5"

Recommended inflation pressure (cold tyres) as per table.

Axle load
kp

13 000
12 R22.5
11.00 R20
12 000
Twin 295 / 80 R22.5
wheels
11 000

10 000

9 000

8 000

12 R22.5
7 000
Single 11.00 R20
wheels 295/80 R22.5
6 000

5 000

4 000
400 500 600 700 800 kPa
2
4 5 6 7 8 kp/cm

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 References to Service Bulletins
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 Volvo Bus Corporation
Göteborg, Sweden

TP 16073/1 English 1500.08.99 Printed in Sweden by Novum Grafiska AB