Professional Documents
Culture Documents
Buses
Section 0 (03)
Specifications B6B LE
TP 16237/1
Contents
page
General ....................................................................... 1
Weights and dimensions ............................................. 1
Type plates .................................................................. 2
Service and Maintenance ............................................ 4
Engine ......................................................................... 6
Fuel system ............................................................. 15
Intake & exhaust ..................................................... 16
Coolings system ...................................................... 17
Electrical System ........................................................ 19
Power Transmission, Rear Axle ................................. 20
Brakes ......................................................................... 25
Front End and Steering ............................................... 30
Frame, Suspension and Wheels .................................. 32
ZF S6-36 4.11:1
4.33:1
4.63:1
1)
Front overhang 2280 mm Optional equipment: – Electrical retarder,
Telma F 90 (with ZF S6-36)
– Differential lock
– Anti-lock brake system (ABS)
– Anti-Spin Regulation (ASR)
with ABS (Special sales order
only)
Weights and dimensions – approx.
Chassis weights (kg)
Front axle ...................................................... 1200
Rear axle ....................................................... 3750
Total .............................................................. 4900
Max. front axle pressure ............................... 4500
Max. rear axle pressure ................................. 8000
Max. GVW ................................................... 12200
4635 WB
Front overhang .............................................. 2280
Wheelbase ..................................................... 4635
Rear overhang ............................................... 2655
Overall length ............................................... 9750
Width ............................................................ 2450 – across front wheels
4100 WB
Front overhang .............................................. 2280
Wheelbase ..................................................... 4100
Rear overhang ............................................... 2655
Overall length ............................................... 9035
Width ............................................................ 2450 – across front wheels
1
Type plates
Product plate
2
Engine certificate plate
3
Service and Maintenance
Lubrication
Engine
Oil quality ..................................................................... Volvo Drain specification VDS-2, VDS, or
API service CE, CF, CF-4, CG-4.
Oil change quantity (incl. oil filter):
D6A ......................................................................... 17 litres (approx.)
Automatic transmission
ZF 4/5HP 500-N
Oil specification ............................................................ ATF Dexron III, Dexron III semi-synthetic,
Dexron III fully synthetic
Oil quantity, when filling empty transmission ............. Approx. 20 litres*
Oil-change quantity, incl. oil cooler ............................. Approx. 14–17 litres*
CAUTION
* Final level must be checked with dipstick.
4
Clutch
Fluid specification ........................................................ SAE J 1703 (DOT 4). Volvo P/N 1381074.
Rear axle
Oil grade ....................................................................... API GL-5 (MIL-L-2105 B or C).
Use the viscosity indicated in the table below.
Oil-change quantity ...................................................... Approx. 12 litres.
Power steering
Power steering
Fluid grade .................................................................... ATF
Fluid-change quantity ................................................... Approx. 16 litres.
Wheel hubs
Lubricant for rear-wheel bearings ................................ Final drive oil, API GL-5 (same as in final drive)
Oil quantity ................................................................... Approx. 0.8 litre per hub.
Lubricant for front-wheel bearings ............................... Lithium/lead-base wheel-bearing grease with EP
additives and a consistency of NGLI-2.
5
Engine – general
Type designation .......................................................... D6A180, D6A210
6
Cylinder head
Type .............................................................................. One head per 3 cylinders
Length ........................................................................... 389 mm
Width ............................................................................ 213 mm
Cylinder block
Length ........................................................................... 796 mm
Height, upper block face –
crankshaft centre (A) min. ............................................ 369.1 mm
Height, lower block face –
crankshaft centre (B) min. ............................................ 90 mm
Piston
7
Piston rings
Compression rings
Number ......................................................................... 2
Upper compression ring height .................................... 3.5 mm
Piston ring gap measured in ring opening .................... 0.425 mm
Lower compression ring height .................................... 2.5 mm
Piston ring clearance in groove .................................... 0.040–0.072 mm
Piston ring gap measured in ring opening .................... 0.425 mm
Gudgeon pins
Clearance, gudgeon pin – connecting rod bushing ....... 0.018–0.026 mm
Gudgeon pin diameter .................................................. 39.996–40.000 mm
8
Valves
Disc diameter:
Intake ....................................................................... 41 mm
Exhaust .................................................................... 37 mm
Stem diameter
Intake ....................................................................... 7.960–7.975 mm
Exhaust .................................................................... 7.935–7.950 mm
Valve sealing surface angle
Intake ....................................................................... 29.5°
Exhaust .................................................................... 44.5°
Valve disc edge
Intake ....................................................................... 1.5 mm
Exhaust .................................................................... 1.5 mm
Seat angle in cylinder head
Intake ....................................................................... 30°
Exhaust .................................................................... 45°
Cylinder head face – valve, recessed ....................... 0–0.4 mm
The valves on D6A can be adjusted according to the two Inlet 0.40 mm
position method. Exhaust 0.55 mm
When No. 1 piston is at T.D.C. after compression, adjust
valves 1, 2, 3, 6, 7, and 10.
When No. 6 piston is at T.D.C. after compression, adjust
valves 4, 5, 8, 9, and 12.
Valve seats
Outer diameter (meas. A) standard ..............................
Intake ....................................................................... 43.582 mm
Exhaust .................................................................... 41.582 mm
Oversize
Intake ....................................................................... 43.782 mm
Exhaust .................................................................... 41.782 mm
Height (meas. B)
Intake ....................................................................... 6.1 mm
Exhaust .................................................................... 8.9 mm
9
Valve seat location
Depth (meas. D)
Intake ....................................................................... 9.0 mm
Exhaust .................................................................... 9.5–9.6 mm
Valve guides
Length ...........................................................................
Intake ....................................................................... 64.5 mm
Exhaust .................................................................... 64.5 mm
Inner diameter
Intake ....................................................................... 8.000–8.015 mm
Exhaust .................................................................... 8.000–8.015 mm
10
Timing gears
Camshaft
Drive ........................................... Gear
Number of bearings .................... 7
Diameter of bearing pins, min:
1st bearing pin ....................... 68.996–69.015 mm
2nd bearing pin ...................... 66.621–66.640 mm
3rd bearing pin ....................... 64.233–64.252 mm
4th bearing pin ....................... 63.446–63.465 mm
5th bearing pin ....................... 61.058–61.077 mm
6th bearing pin ....................... 60.271–60.290 mm
7th bearing pin ....................... 56.296–56.315 mm
11
Crank mechanism
Oversize:
0.2 mm (axial bearing 0.2) ... 44.175–44.225 mm
0.4 mm (axial bearing 0.2) ... 44.375–44.425 mm
0.6 mm (axial bearing 0.3) ... 44.575–44.625 mm
12
Connecting rod bearing pins
Diameter (Ø) for machining,
standard ................................... 63.448–63.462 mm
Undersize:
0.25 mm ................................. 63.194–63.208 mm
0.50 mm ................................. 62.940–62.954 mm
0.75 mm ................................. 62.686–62.700 mm
1.00 mm ................................. 62.432–62.446 mm
1.25 mm ................................. 62.178–62.192 mm
Connecting rods
Length, centre–centre (E) ........... 230 mm
Marking:
Connecting rod resp. cap ....... 1 to 6
“FRONT” on rod turned ........ Forwards
Bushing bore (G) ........................ 40.018–40.022 mm
Axial clearance, connecting rod –
crankshaft max. ....................... 0.250 mm
Radial clearance .......................... 0.066–0.112 mm
13
Lubricating system
Oil valves
A. Piston cooling valve C. Reduction valve
Marking ........................................ White Marking ........................................ Brown
14
Fuel system
Injection pump
Type .............................................................................. Denso EP 9
Governor type ............................................................... R 901 H
Direction of rotation ..................................................... Clockwise
Firing sequence ............................................................. 1-5-3-6-2-4
Injection timing:
D6A 210 .................................................................. 7.5±0.5° B.T.D.C.
D6A 180 .................................................................. 8.0±0.5° B.T.D.C.
Throttle control ............................................................. VDO Mannesmann-electronic
Feed pump
Type .............................................................................. Denso
Pressure ......................................................................... 100–400 kPa
Overflow valve
Designation ................................................................... 210
Opening pressure .......................................................... 2.5–2.7 bar
Injector
Type .............................................................................. 2- spring
Designation (D6A 180/210) ......................................... DLLA 140 P646
Number marking (complete injector) .......................... 6140
Opening pressure .......................................................... 23.5±0.98 MPa
Fuel filters
Number ......................................................................... One
Fuel tanks
Capacity ........................................................................ 2 x 125 litres
15
Engine control – VDO electronic
Electronic Control Unit (ECU)
Voltage .................................................................... 12V/24V
Separate fuse supply ................................................ 16 A
Parameters ............................................................... Programmed to suit installation
Throttle sender
Voltage supply ......................................................... 5v (max. 10V)
Output voltage at pin 3 with 5V supply:
0° – idle ................................................................... 0.225–0.265 V
60±2° – full throttle ................................................. 2.68–3.19 V
Safety contact:
open when lever is at low idle stop
closes at lever angle ................................................. 3±2° from idle
Actuator
Voltage .................................................................... 24 V
Output voltage at pin 6 with 24 V supply:
0° – idle ................................................................... 21.6 V
30° ........................................................................... 15.2 V
60° ........................................................................... 8.8 V
90° – full throttle ..................................................... 2.4 V
Safety contact:
closed when lever is at low idle stop
closes at lever angle ................................................. 21°–12.5° before low idle stop
Starting heater
Voltage ......................................................................... 24 V
Cooling system
General
Type .............................................................................. Pressurised
Pressure valve opens at ................................................. 50 kPa
16
Coolant
Type .............................................................................. C
Consists of .................................................................... Anti-corrosion additives
Colour ........................................................................... Blue-green
Coolant pump
Type .............................................................................. Gear driven, centrifugal
Thermostat
Type .............................................................................. Plunger
Number ......................................................................... One
Opening temperature .................................................... 82°C
Cylinder head
Max. pressure when checking for leakage.................... 150 kPa
Wear tolerances
Cylinder liners
Cylinder liners (pistons and piston rings) should be renewed
with a wear of 0.35–0.40 mm, or if oil consumption is high.
Crankshaft
Max. out of round – main and connecting rod pins ...... 0.08 mm
Max. taper – main and connecting rod pins.................. 0.05 mm
Max. axial clearance on crankshaft .............................. 0.40 mm
Max. throw on centre journalling ................................. 0.15 mm
Connecting rods
Straightness –
max. deviation on a measuring length of 100 mm ....... 0.01 mm
Warp –
max. deviation on a measuring length of 100 mm ....... 0.10 mm
Valves
Valve stem, max. wear ................................................. 0.02 mm
Max. clearance, stem – guide:
Intake ....................................................................... 0.33 mm
Exhaust .................................................................... 0.38 mm
17
Camshaft
Max. out of round (with new bearings) ........................ 0.05 mm
Bearings, max. wear ..................................................... 0.05 mm
Lift height, min.
Intake ....................................................................... 8.33mm
Exhaust .................................................................... 8.33 mm
Flywheel, installed
Max. axial throw at radius 150 mm
(manual gearbox) .......................................................... 0.15 mm
Number of teeth ............................................................ 140
Tightening torques
Nm kgf m
Main bearings .............................................................. 190±10 19.0±1.0
Connecting rod bearings .............................................. 150±10 15.0±1.0
Axial journalling, crankshaft ....................................... 55±5 5.5±0.5
Timing gear casing ...................................................... 33±4 3.3±0.4
Gear wheel, camshaft .................................................. 60±7 6.0±0.7
Gear wheel, injection pump drive................................ 48±4 4.8±0.4
Idler gear journalling ................................................... 90±9 9.0±0.9
Bearing bracket, rocker arm shaft................................ 50±7 5.0±0.7
Oil sump ...................................................................... 24±3 2.4±0.3
Drain plug, oil sump .................................................... 80±8 8.0±0.8
Flywheel ...................................................................... 190±10 19.0±1.0
Flywheel housing ......................................................... 140±14 14.0±1.4
Pulley, crankshaft ........................................................ 90±9 9.0±0.9
Centre bolt, crankshaft ................................................. 260±25 26.0±2.5
Nut, piston cooling nozzle ........................................... 33±4 3.3±0.4
Bracket, lub. oil pump ................................................. 65±7 6.5±0.7
Idler gear, lub. oil pump .............................................. 33±4 3.3±0.4
Injection pump to timing gear casing .......................... 48±4 4.8±0.4
Injection pump to bracket ............................................ 24±3 2.4±0.3
Injection pump bracket to cylinder block .................... 48±4 4.8±0.4
Nut for retainer, injector .............................................. 50±5 5.0±0.5
Support bearing cap, injection pump ........................... 24±3 2.4±0.3
Exhaust manifold ......................................................... 48±5 4.8±0.5
Cylinder head
Note: Tighten in sequence as shown
Tighten in four stages:
Stage 1 ...................................... 30 3.0
Stage 2 ...................................... 90 9.0
Stage 3 ...................................... 90 9.0
Stage 4 (Angle tightening) ....... 60°
18
Electrical system and instruments
System voltage .............................................................. 24 V
Batteries
Type .............................................................................. Low maintenance
Voltage (each battery) .................................................. 12 V
Capacity ........................................................................ 2 x 110 Ah (2 x 170 Ah – option)
Polarity ......................................................................... Negative earth
Specific gravity of electrolyte:
Battery fully charged ............................................... 1.28
Charging required .................................................... 1.24
Recommended charging voltage .................................. approx. 28 volts
Charging time (battery flat) .......................................... approx. 16 hours
Charging current ........................................................... approx. 6 A (one battery)
approx. 12 A (both batteries)
Alternator – 1 x 80 A (Option – 2 x 80 A)
Type .............................................................................. Bosch N1 28 V 10/80
Voltage ......................................................................... 28 V
Output ........................................................................... 2.24 kW
Rotor resistance (across slip rings) ............................... 7.5–8.3 ohm
Stator resistance (between phases) ............................... 0.10–0.125 ohm
Minimum length – brushes ........................................... 5.0 mm
Minimum diameter – slip rings .................................... 26.8 mm
Max. radial run-out, rotor ............................................. 0.05 mm
Charging current
– at operating temperature approx. 60°C
– alternator speed:
1500 r/min ............................................................... 10–12 A
6000 r/min ............................................................... 78–82 A
Tightening torques
Pulley nut M16 ............................................................. 50 Nm (5.0 kpm)
4 through screws M5 .................................................... 4.8 Nm (0.48 kpm)
“B+” M8 ....................................................................... 7.5–8.0 Nm (0.75–0.80 kpm)
“B–” M6 ....................................................................... 4.8–6.8 Nm (0.48–0.68 kpm)
“W” M5 ........................................................................ 2.7–2.8 Nm (0.27–0.38 kpm)
“D+” M4 ....................................................................... 1.4–2.0 Nm (0.14–0.20 kpm)
Charging regulator
Designation ................................................................... EL 28V (1197 311 304)
Testing conditions:
Fully charged battery
Temperature at regulator .............................................. 20°C
Alternator speed ............................................................ 4000 r/min
Alternator load .............................................................. 10 A
Control voltage between B+ and D+
(reading within 1 minute) ............................................. 27.6–28.4 V
19
Starter motor
Type .............................................................................. Denso 128000-7603
Voltage ......................................................................... 24 V
Rating ........................................................................... 4.5 kW
Starter relay
Min. actuating voltage .................................................. 18 V
Fire detection
Sensors:
Type .............................................................................. G6W – normally closed contacts
Break temperature: .......................................................
Above starter motor ................................................. 110°C
Above fuel injection pump ........................................... 110°C
Above turbo-charger ................................................ 155°C
20
Manual gearbox S6-36
Reduction ratios:
1st gear .......................................................................... 7.43:1
2nd gear ........................................................................ 4.32:1
3rd gear ......................................................................... 2.57:1
4th gear ......................................................................... 1.62:1
5th gear ......................................................................... 1.21:1
6th gear ......................................................................... 1.00:1
Reverse ......................................................................... 6.67:1
Wear limits
Clearance of fulcrum pads in guide grooves or sliding
sleeves (new condition) ............................................ 0.4–0.7 mm
Tightening Torques
Nm
Hexagon nut on output ................................................. 360
Hinged bolts M 18 x 1.5 in housing ............................. 160
Speedo connection M 30 x 1.5 ..................................... 100
Screw plug M 24 x 1.5
(oil filler and oil control plugs) in housing .............. 60
Screw plug M 20 x 1.5 for detent element on selector
housing .................................................................... 50
21
Automatic transmission (ZF)
Coupling ............................................ Torque convertor coupling, with lock-up clutch, and integral retarder.
R Reverse Reverse
N Neutral Neutral
D 1, 2, 3, 4 1, 2, 3, 4, 5
2 1, 2, 3 1, 2, 3, 4
1 1, 2 1, 2
22
Oil pressures
Check values at 60–80°C
oil temperature (transmission run warm) MPa bar engine speed r/min
1. Main pressure, N-position ....................................... 1.8±0.2 18±2 approx. 700–2000
D-position with lock-up
clutch engaged ................................ 1.0±0.2 10±2 above 2000
2. Modulator pressure ................................................... 0.60–0.65 6.0–6.5
drops to pressure adapted to respective gears at gear-change
(during approx. 1 second), approx. 0.5 bar N/D at idling.
Clutch plates
Friction plates and steel plates, cone ............................ max. 0.3 mm
If burns or other damages occur clutch plates
must be exchanged.
Rear cover, axial clearance, bearing, output shaft ........ 0.02 to 0.07 (+0.05 constant, at 20°C)
Tightening torques
Nm kgf m
Drain plug, oil sump .................................................... 50–60 5–6
oil cooler .................................................. 21–25 2.1–2.5
Retaining bolts, oil filter cover and oil sump ............... 25 2.5
Retaining bolts, engine/transmission bolting
large bolts (M12) ..................................................... 70–90 7–9
slotted-head bolts, ring gear (two M8) .................... 20–26 2.0–2.6
Retaining nuts, flywheel casing .................................... 56±10 5.6±1.0
Retaining bolts, flexplate/flywheel ............................... 160±25 16±2.5
23
Rear axle
Type .............................................................................. Fully floating
Track ............................................................................. 1720 mm
Tightening torques
Nuts rear axle casing .................................................... 128±13 Nm (12.8±1.3 kgf m)
Oil plug ......................................................................... 61±7 Nm (6.1±0.7 kgf m)
Rear axle
Designation ................................................................... RS 0824
Type .............................................................................. Single reduction hypoid
Reduction ratios ............................................................ 4.11:1
4.33:1
4.63:1
Tightening torques
Differential case capscrew ............................................ 95–119 Nm
Ring gear nut ................................................................ 292–346 Nm
Pinion bearing cage capscrew....................................... 155–190 Nm
Diff. bearing cap capscrew ........................................... 475–580 Nm
Diff. carrier to housing capscrew ................................. 115–140 Nm
Carrier to housing nut ................................................... 270–331 Nm
Magnetic plug ............................................................... 54–81 Nm
Drain plug ..................................................................... 54–81 Nm
Thrust screw nut ........................................................... 201–245 Nm
Pinion nut ...................................................................... 510–625 Nm
Propeller shaft
Size ............................................................................... 1600
Flange, max. permitted axial throw .............................. 0.1 mm
Flange, max. permitted radial throw ............................. 0.1 mm
Lubricant, universal joints ............................................ Chassis grease
Tightening torque, flange bolts ..................................... 54 Nm (5.4 kgf m)
24
Brakes
Wheel brakes
Brake drum
Diameter, standard ...................................................... 360.000–360.230 mm
oversize I .................................................... 361.400–361.730 mm
Width, machined ........................................................... 184±1 mm
Permitted wear (incl. turning) ....................................... 3 mm
Permitted out-of-round ................................................. 0.25 mm
Permitted out-of-round after machining ....................... 0.1 mm
Brake lining
Type .............................................................................. Volvo 46
Blocks per shoe ............................................................. 2
Width ............................................................................ 162.0–163.0 mm
Length, leading shoe ..................................................... 350 mm (+ phase 40 mm)
trailing shoe ............................................................ 280 mm
Thickness, new linings
leading shoe ............................................................. 11.3 mm
trailing shoe ............................................................. 9.6 mm
Thickness, minimum permitted .................................... 5.0 mm
Number of rivets per shoe ............................................ 28
Gross Net
Area, leading shoe ....................................................... 595 cm2 540 cm2
trailing shoe ....................................................... 476 cm2 432 cm2
total (4 wheels) .................................................. 4284 cm2 3888 cm2
25
Lining-to drum clearance
The automatic adjustment keeps the clearance
between .................................................................... 0.35–1.55 mm
Each shoe can have different clearances within
the tolerance.
Adjustment measurement ............................................. 1–1.5 mm
Brake cylinder
Size rear ........................................................................ 12 in2
Size – front ................................................................... 17 in2
Tightening torques
Torque plate, front wheels, M14 .................................. 190±10 Nm
rear wheels, M16 .................................... 295±20 Nm
Brake cylinder flange, M10 .......................................... 40±5 Nm
Roller tappet locating pins ............................................ 13.5±1.5 Nm
Compressor
Designation ................................................................... LP 4934
Type .............................................................................. Piston-compressor
Compressor max. operating speed ................................ 3000 rev/min
Air capacity at compressor speed
2000 rev/min (engine speed 2200 rev/min)
and backpressure 700 kPa ............................................ 710 dm3/min
Number of cylinders ..................................................... 2
Bore, stnd. ................................................................... 88.000–88.029 mm
classification marking ....................................... 3, 4, 5
Stroke ............................................................................ 50 mm
Capacity, total ............................................................... 600 cm3
Valves, type .................................................................. Disc
Piston
Bore, std. ..................................................................... 87.935–787.964 mm
classification marking/diam. ............................. 3/87,94 mm
4/87,95 mm
5/87,96 mm
Clearance piston/cylinder ............................................. 0.06–0.08 mm
max. permitted wear ................................................ 0.16 mm
Piston ring
Number per piston ........................................................ 3 (1 oil scraper ring)
Clearance in piston groove ........................................... 0.01–0.04 mm
max. permitted wear ................................................ 0.05 mm
Ring gap, max. permitted wear ..................................... 1.20 mm
Gudgeon pin
Diameter ....................................................................... 17.995–18.000 mm
Fit in piston ................................................................... 0.004–0.013 mm
max. permitted wear ................................................ 0.04 mm
Fit in connecting rod ..................................................... 0.016–0.032 mm
max. permitted wear ................................................ 010 mm
26
Crankshaft
Connecting-rod bearing journal, diameter .................... 36.984–37.000 mm
Connecting-rod bearing, clearance ............................... 0.010–0.038 mm
max. permitted wear ................................................ 0.20 mm
Axial clearance, worn crankshaft, max. ....................... 0.50 mm
Main bearings, diameter ............................................... 37.944–37.960
Main bearings, clearance .............................................. 0.040–0.081 mm
max. permitted wear ................................................ 0.13 mm
Axial clearance, max. with wear .................................. 0.60 mm
Tightening torque
Driving gear wheel ....................................................... 200+50 Nm
Cylinder head* .............................................................. 30.0+3 Nm
Disc valve, .................................................................. 12±0.6 Nm
Connecting rods ............................................................ 13+3 Nm
End cover ...................................................................... 22+2 Nm
Bottom cover ................................................................ 12±1 Nm
* Tightening sequence
Air dryer
Make and ref. ................................................................ Haldex AT 83357
Type .............................................................................. Single tower with integral governor valve
Cut-out pressure ............................................................ 8.5 bar ±0.2 bar
Pressure range ............................................................... 0.8 bar ±0.2 bar
Air tanks
Volume, purge tank (air dryer) .................................. 6-litre
primary/suspension tank ............................. 30-litre
front circuit tank .......................................... 25-litre
rear circuit tank ........................................... 30-litre
Tightening torques
Tightening torques for brake pipe connections:
Plastic piping:
1/4" .......................................................................... 15 Nm (1.5 kgf m)
3/8" .......................................................................... 20 Nm (2.0 kgf m)
1/2" .......................................................................... 30 Nm (3.0 kgf m)
5/8" .......................................................................... 40 Nm (4.0 kgf m)
27
Safety valve
Location/opening pressure ............................................ Purge tank – 1.0 bar,
air dryer port 12–13.0 bar,
primary/suspension tank – 9.3 bar
Pressure switches 4 2
1. Brake lights – normally open ................................... Closes at 0.3±0.2 bar
2. Park brake warning lamp – normally closed ............ Opens at 5.4±0.3 bar
3
3. NBS from footbrake – normally open ...................... Closes at 0.8±0.15 bar
4. NBS from park brake – normally closed .................. Opens at 0.7±0.3 bar Switches viewed
from front of bus
Footbrake valve
With manual and automatic gearbox:
Type .............................................................................. 2-circuit, floor mounted pedal
Max. permitted difference in brake pressure between
both circuits throughout entire pressure range ........ 20 kPa (0.2 kgf/cm2)
Modulator valve pressure with pedal travel*
7–30 mm (2–9°)....................................................... 0–320 kPa (0–3.2 kgf/cm2)
more than 30 mm (9°) ................................................... 320 kPa (3.2 kgf/cm2)
* Not used with manual gearbox.
Quick-release valve
Type, designation ......................................................... KX 1294/1 (front circuit)
28
Relay valve
Make, ref. ...................................................................... Bosch, 0 481 026 015
Two-way valve
Type, designation ......................................................... DC 1
Blocking valve
Valve closes when pressure drops below ..................... 340–400 kPa (3.4–4.0 kgf/cm2)
Control button remains in pushed-in position if tank
pressure exceeds closing pressure.
ABS/ASR
Electronic Control Unit (ECU):
Type ......................................................................... Wabco C2–4S/4M
Voltage ......................................................................... 24 V±25%
29
Front end and steering
Wheel angles
Caster ............................................................................ 2±0.5°
Camber ......................................................................... 0.75±0.5°
Toe-in ........................................................................... Parallel ± 1.5 mm
King pin inclination ...................................................... 5.75±0.25°
Max. steering angle, inner wheel .................................. approx. 48°
Front axle
Type .............................................................................. Independent Front Suspension (IFS) with
unequal length double wishbones
King pin diameter (in bush) .......................................... 45 mm
Shims for king pin adjustment ...................................... 0.10, 0.35, 1.00 mm
Axial clearance for spindle bearing journal .................. 0.05–0.15 mm
Power steering
Steering gear
Make and type .............................................................. ZF Servocom 8095 recirculating ball
Ratio ............................................................................. Variable – straight ahead 15.7:1
– at full lock (2.2 turns of wheel) 18.5:1
Pump
Make and type .............................................................. ZF vane-type pump
Drive ............................................................................. Gear-driven
Max. pump pressure ..................................................... 13 MPa (130 kgf/cm2)
Min. capacity (pump speed)
8.3 r/s (500 r/min), 5 MPa (50 kgf/cm2) and 50°C .. 10.5 litres/min
Max. capacity ............................................................... 16 litres/min
Reduction ratio between engine and pump................... 1:1.58
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Tightening torques
Nm
Steering
Steering wheel nut ........................................................ 75
Nut, pitman arm ............................................................ 550
Attaching screw, steering gear – bracket ...................... 560*
Attaching screw, bracket, steering gear chassis frame . 220
Castle nut, link rods and bearing for intermediate
steering arm .............................................................. 200 and then to nearest split pin hole
Clamping screw, steering shaft-/steering shaft joint .... 60
Attaching screw, angle gear.......................................... 85
Attaching screw, bearing/anchorage bracket,
intermediate steering arms ........................................ 140
Clamping screw, link rods ............................................ 47.5
Attaching screw, steering arms ..................................... 750*
Castle nut, axle spindle ................................................. 500 and then to nearest split pin hole
Attaching screw, axle spindle cover. ............................ 40
Lock nut, servo pump drive .......................................... 100
Attaching screw, steering gear cover ............................ 285
Lock nut, load relief valve ............................................ 30
Wheel suspension
Castle nut – king pin ..................................................... 230*
Bolt M16, upper support arm ....................................... 220
Bolt M20, upper support arm ....................................... 430
Screw M10, spindle bushing (upper support arm) ....... 48
Attaching screw, inner spindle (upper support arm) .... 48
Bolt M20, lower support arm ....................................... 430
Screw M20, lower support arm (distance rod) ............. 430
Screw M12, spindle bushing (lower support arm) ....... 85
Screw M16 (“10.9”), attaching member,
lower support arm ..................................................... 275
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Frame, suspension and wheels
Air Suspension
Type .............................................................................. Full air suspension with electronic control – ECS
SKON (switch configuration see ECU label) .............. SKON – S = chassis stays at height reached
when kneel switch is released.
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Ferry lift
Max. lift – front and rear, both sides ............................ approx. 55 mm
Kneeling
Kneel dimension – front both sides .............................. approx. 60 mm
Dampers
Front
Type .............................................................................. Telescopic
Number ......................................................................... 2
Rear
Type .............................................................................. Telescopic
Number ......................................................................... 4
Wheels
Hubs
Axial clearance of front and rear wheel bearings ......... 0.04–0.12 mm
Oil volume/hub, rear wheels ......................................... 0.8 litres (same oil as in final drive)
Rims
Type .............................................................................. Steel disc – 8 studs
Dimensions ................................................................... 7.5–19.5"
Tightening torques
Nm kgf m
Lock-nut for front-wheel hub ....................................... 105 10.5
Front-wheel hub cap ..................................................... 250 25
Lock nut for rear-wheel hub ......................................... 300 30
Oil plug ......................................................................... 25 2.5
Wheel nuts * ................................................................. 525±75 52.5±7.5
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*Tightening wheel nuts
Initial tightening
1. Tighten the nuts in the sequence illustrated to about 300 Nm.
2. In the same sequnce, thighten the nuts to 525±75 Nm.
Check/tightening
Check/tighten the wheeel nuts after the first 100–150 km.
and every 6 monthths
Tyres
Type .............................................................................. Tubeless, radial, low profile
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References to Service Bulletins
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References to Service Bulletins
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Volvo Bus Corporation
Göteborg, Sweden